Module-based energy systems having converter-source modules and methods related thereto

ABSTRACT

Module-based energy systems are provided having multiple converter-source modules. The converter-source modules can each include an energy source and a converter. The systems can further include control circuitry for the modules. The modules can be arranged in various ways to provide single phase AC, multi-phase AC, and/or DC outputs. Each module can be independently monitored and controlled.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. ProvisionalApplication Ser. No. 62/826,158, filed Mar. 29, 2019, U.S. ProvisionalApplication Ser. No. 62/826,238, filed Mar. 29, 2019, and U.S.Provisional Application Ser. No. 62/906,007, filed Sep. 25, 2019, all ofwhich are incorporated by reference herein for all purposes.

FIELD

The subject matter described herein relates generally to module-basedenergy systems and modules for use therein, and systems, devices, andmethods that facilitate the interconnection and control of modules inmodule-based energy systems.

BACKGROUND

Energy systems having multiple energy sources or sinks are commonplacein many industries. One example is the automobile industry. Today'sautomotive technology, as evolved over the past century, ischaracterized, amongst many things, by an interplay of motors,mechanical elements, and electronics. These are the key components thatimpact vehicle performance and driver experience. Motors are of thecombustion or electric type and one usually finds one motor per car,exceptions being cars with hybrid drivetrains, featuring a combinationof a combustion engine with one or two electric motors, or performanceoriented electric vehicles that are outfitted with two motors. In almostall cases the rotational energy from the motor(s) is delivered via a setof highly sophisticated mechanical elements, such as clutches,transmissions, differentials, drive shafts, torque tubes, couplers, etc.These parts control to a large degree torque conversion and powerdistribution to the wheels and are key elements to define theperformance of the car. They also impact road handling. Over the yearsindividual car manufacturers have highly optimized these mechanicalparts to provide better performance, higher fuel efficiency andultimately differentiation in the market place. On the control side,apart from driver comforts such as entertainment, navigation and humanmachine interface elements, there are typically only a few clusters ofspecialty electronics hardware and embedded software thatcontrol/optimize motors, clutch/transmission operation and roadholding/handling.

An EV comprises various electrical systems that are related to thedrivetrain including, among others, the battery, the charger and motorcontrol. A short inventory of the present capabilities and shortcomingsof these electrical systems are described below.

Conventional Battery Design

High voltage battery packs are typically organized in a serial chain oflower voltage battery modules. Each such module is further comprised ofa serially connected set of individual cells and a simple embeddedbattery management system to regulate basic cell relatedcharacteristics, such as state of charge and voltage. Electronics withmore sophisticated capabilities or some form of smart interconnectednessare absent. As a consequence, any monitoring or control function ishandled by a separate system, which, if at all present elsewhere in thecar, lacks the ability to monitor individual cell health, state ofcharge, temperature and other performance impacting metrics. There isalso no ability to adjust power draw per individual cell in any form.Some of the major consequences are: (1) the weakest cell constrains theoverall performance of the entire battery pack, (2) failure of any cellor module leads to a need for replacement of the entire pack, (3)battery reliability and safety are considerably reduced, (4) batterylife is limited, (5) thermal management is difficult, (6) battery packsalways operate below maximum capabilities, (7) sudden inrush into thebattery packs of regenerative braking derived electric power cannot bereadily stored in the batteries and will require dissipation via a dumpresistor.

Conventional Charger Design

Charging circuits are typically realized in separate on-board systems.They stage power coming from outside the EV in the form of an AC signalor a DC signal, convert it to DC and feed it to the battery pack(s).Charging systems monitor voltage and current and typically supply asteady constant feed. Given the design of the battery packs and typicalcharging circuits, there is little ability to tailor charging flows toindividual battery modules based on cell health, performancecharacteristics, temperature, etc. Charging cycles are also typicallylong as the charging systems and battery packs lack the circuitry toallow for pulsed charging or other techniques that would optimize thecharge transfer or total charge achievable.

Conventional Motor Control Design

Conventional controls contain DC to DC conversion stages to adjustbattery pack voltage levels to the bus voltage of the EV's electricalsystem. Motors, in turn, are then driven by simple two-level multiphaseconverters that provide the required AC signal(s) to the electric motor.Each motor is traditionally controlled by a separate controller, whichdrives the motor in a 3-phase design. Dual motor EVs would require twocontrollers, while EVs using four in-wheel motors would require 4individual controllers. The conventional controller design also lacksthe ability to drive next generation motors, such as switch reluctancemotors (SRM), characterized by higher numbers of pole pieces. Adaptationwould require higher phase designs, making the systems more complex andultimately fail to address electric noise and driving performance, suchas high torque ripple and acoustical noise.

Many of these deficiencies apply not only to automobiles but other motordriven vehicles, and also to stationary applications to a certainextent. For these and other reasons, needs exist for improved systems,devices, and methods for energy systems for the vehicular industry andelsewhere.

SUMMARY

Example embodiments of systems, devices, and methods are provided hereinfor module-based energy systems widely relevant to many applications. Inmany of these embodiments, a module-based energy system includesmultiple modules, where each module includes at least an energy sourceand a converter. More complex configurations of each module are alsodisclosed. The modules of the system can be connected together indifferent arrangements of varying complexities to perform functionsspecific to the particular technological application to which the systemis applied. The system can be configured to monitor status information,at least one operating characteristic, or other parameter of each modulerepeatedly during use of the system, assess the state of each modulebased on that monitored status information, operating characteristic, orother parameter, and control each module independently in an effort toachieve and/or maintain one or more desired targets, such as electricalperformance, thermal performance, lifespan, and others. This control canoccur to facilitate energy provision from the system (e.g., discharging)and/or energy consumption (e.g., charging). Numerous exampleapplications of these systems, devices, and methods are described.

In many example embodiments, the at least one energy source of themodule can include a capacitor (such as an ultra-capacitor orsuper-capacitor), a battery, and a fuel-cell.

In many example embodiments, the system can include at least twoconverter-source modules connected in a one-dimensional array or in amulti-dimensional array. At least two one-dimensional arrays can beconnected together, for example, at different rows and columns directlyor by one or more additional converter-source modules. In suchconfigurations, an output voltage of any shape and frequency can begenerated at the outputs of the module-based energy system as asuperposition of output voltages of individual converter-source modules.

The various interconnected architectures of the example embodimentsenable inter-phase power management within a single module-based energysystem (e.g., a battery pack) and inter-system power management betweenmultiple module-based energy systems (e.g., battery packs), as well asconnection of auxiliary loads to the system(s), and maintenance ofuniform distribution of energy provided to those loads from allconverter-source modules of such systems.

The various interconnected architectures of the example embodiments alsoenable the control of power sharing among converter-source modules. Suchcontrol enables, for example, regulation of parameters like State ofCharge of the energy sources of the converter-source modules to bebalanced, in real time and continually during cycling, as well as atrest, which fosters utilization of the full capacity of each energysource regardless of possible differences in their capacities. Inaddition, such control can be used to balance the temperature of theenergy sources of the converter-source modules. Temperature balancing,for example, can increase the power capability of the system (e.g., abattery pack) and provide more uniform aging of the energy sourcesregardless of their physical location within the system and differencesin their thermal resistivity.

Other systems, devices, methods, features and advantages of the subjectmatter described herein will be or will become apparent to one withskill in the art upon examination of the following figures and detaileddescription. It is intended that all such additional systems, methods,features and advantages be included within this description, be withinthe scope of the subject matter described herein, and be protected bythe accompanying claims. In no way should the features of the exampleembodiments be construed as limiting the appended claims, absent expressrecitation of those features in the claims.

BRIEF DESCRIPTION OF FIGURES

The details of the subject matter set forth herein, both as to itsstructure and operation, may be apparent by study of the accompanyingfigures, in which like reference numerals refer to like parts. Thecomponents in the figures are not necessarily to scale, emphasis insteadbeing placed upon illustrating the principles of the subject matter.Moreover, all illustrations are intended to convey concepts, whererelative sizes, shapes and other detailed attributes may be illustratedschematically rather than literally or precisely.

FIGS. 1A, 1B and 1C are block diagrams depicting example embodiments ofa module-based energy system.

FIG. 2 is a block diagram depicting an example embodiment of aconverter-source module (ConSource V1) with a local control device (LCD)interconnected to a master control device (MCD), according toembodiments of the present disclosure.

FIG. 3 is a block diagram depicting another example embodiment of aconverter-source module (ConSource V2) with an LCD interconnected to anMCD, according to embodiments of the present disclosure.

FIG. 4 is a block diagram depicting another example embodiment of aconverter-source module (ConSource V3) with an LCD interconnected to anMCD and optional auxiliary loads, according to embodiments of thepresent disclosure.

FIG. 5A is a schematic depicting an example embodiment of a converter(Converter V1) shown in FIG. 2, according to embodiments of the presentdisclosure.

FIG. 5B is a schematic depicting an example embodiment of a converter(Converter V2) shown in FIGS. 2 and 3, according to embodiments of thepresent disclosure.

FIGS. 6A, 6B and 6C are diagrams depicting example embodiments of energystorage elements for use as an energy source shown in FIGS. 1, 2 and 3,according to embodiments of the present disclosure.

FIGS. 7A, 7B and 7C are schematics depicting of example embodiments foruse as the energy buffer shown in FIGS. 1, 2 and 3, according toembodiments of the present disclosure.

FIGS. 8A, 8B, 8C, 8D, 8E, and 8F are diagrams depicting exampleembodiments for use as energy source 2 shown in FIG. 3, according toembodiments of the present disclosure.

FIG. 9 is a graph depicting the output voltage from an example converteraccording to embodiments of the present disclosure.

FIG. 10 is a graph depicting the output voltage from an examplemodule-based energy storage system having six example converter-sourcemodules, according to embodiments of the present disclosure.

FIG. 11 is a block diagram depicting an example embodiment of power flowmanagement for the example converter-source module (ConSource V2) shownin FIG. 3, according to embodiments of the present disclosure.

FIGS. 12A and 12B are graphs depicting example waveforms of aconverter-source (ConSource V2) module shown in FIG. 3, in which theconverter V2 provides a secondary function of reduction of a secondorder current harmonic.

FIG. 13 is a block diagram depicting an example embodiment of power flowmanagement for the converter-source (ConSource V3) module shown in FIG.4, according to embodiments of the present disclosure.

FIGS. 14A, 14B, 14C, and 14D are graphs depicting an example embodimentof pulse width modulation applicable to example embodiments ofmodule-based energy systems.

FIG. 15 is a schematic depicting an example one-dimensional array ofconnected example converter-source modules, according to exampleembodiments of the present disclosure.

FIG. 16 is a schematic depicting an example two-dimensional array ofconnected example converter-source modules, according to exampleembodiments of the present disclosure.

FIG. 17 is a schematic depicting another example two-dimensional arrayof connected example converter-source modules, according to exampleembodiments of the present disclosure.

FIG. 18 is a schematic depicting an example system having multipleexample converter-source modules connected in a three-dimensional array,according to example embodiments of the present disclosure.

FIG. 19 is a schematic depicting another example system having multipleexample converter-source modules connected in a three-dimensional array,according to example embodiments of the present disclosure.

FIG. 20 is a schematic depicting another example system having multipleexample converter-source modules connected in a three-dimensional array,according to example embodiments of the present disclosure.

FIG. 21 is a schematic depicting an example system having multipleexample converter-source modules connected in a multi-dimensional array,according to example embodiments of the present disclosure.

FIG. 22 is a schematic depicting an example system having multipleexample converter-source modules connected in a three-dimensional array,and connected to an electrical motor, according to example embodimentsof the present disclosure.

FIG. 23 is a schematic depicting another example system having multipleexample converter-source modules connected in a three-dimensional array,and connected to an electrical motor, according to example embodimentsof the present disclosure.

FIG. 24 is a schematic depicting another example system having multipleexample converter-source modules connected in a three-dimensional array,and connected to an electrical motor and auxiliary loads, according toexample embodiments of the present disclosure.

FIG. 25 is a schematic depicting another example system having multipleexample converter-source modules connected in a three-dimensional array,and connected to an electrical motor and auxiliary loads, according toexample embodiments of the present disclosure.

FIG. 26 is a schematic depicting another example system having multipleexample converter-source modules connected in a six-dimensional array,and connected to a six-phase electrical motor and auxiliary loads,according to example embodiments of the present disclosure.

FIG. 27 is a schematic depicting another example system having multipleexample converter-source modules connected in a three-dimensional array,and connected to two three-phase electrical motors and auxiliary loads,according to example embodiments of the present disclosure.

FIG. 28 is a schematic depicting another example system having multipleexample converter-source modules connected in a three-dimensional array,and connected to a three-phase open-winding electrical motor andauxiliary loads, according to example embodiments of the presentdisclosure.

FIG. 29 illustrates a schematic depicting another example system havingmultiple example converter-source modules connected in athree-dimensional array, and connected to two three-phase open-windingelectrical motor and auxiliary loads, according to example embodimentsof the present disclosure.

FIG. 30 is a schematic depicting an example embodiment of a single-phasebalancing controller, for use with example embodiments of the presentdisclosure.

FIG. 31 depicts a phasor diagram of voltage sharing control for anexample single-phase system, for use with example embodiments of thepresent disclosure.

FIG. 32 depicts a schematic depicting an example embodiment of asingle-phase balancing controller, for use with example embodiments ofthe present disclosure.

FIGS. 33A and 33B depict phasor diagrams of voltage sharing control fora three-phase structure for (A) intra-phase balancing only and (B)intra-phase and inter-phase balancing.

FIGS. 34A and 34B depict phasor diagrams of voltage sharing control fora three-phase structure with common modules with intra-phase andinter-phase balancing through (A) common modules and (B) common modulesand neutral point shift.

FIGS. 35A and 35B depict phasor diagrams of voltage sharing control withintra-phase and inter-phase balancing for four-phase systems with (A)neutral point shift and (B) common modules and neutral point shift.

FIGS. 36A and 36B depict phasor diagrams of voltage sharing control withintra-phase and inter-phase balancing for five-phase systems with (A)neutral point shift and (B) common modules and neutral point shift.

FIGS. 37A and 37B depict phasor diagrams of voltage sharing control withintra-phase and inter-phase balancing for six-phase systems with (A)neutral point shift and (B) common modules and neutral point shift.

FIGS. 38A and 38B depict phasor diagrams of voltage sharing control withintra-phase and inter-phase balancing for an example system shown inFIG. 27 through (A) common modules and (B) common modules and neutralpoint shift.

FIGS. 39A and 39B depict phasor diagrams of voltage sharing control withintra-phase and inter-phase balancing for systems shown in FIG. 28through (A) common modules and (B) common modules and neutral pointshift.

FIGS. 40A and 40B depict phasor diagrams of voltage sharing control withintra-phase and inter-phase balancing for systems shown in FIG. 29through (A) common modules and (B) common modules and neutral pointshift.

FIGS. 41 and 42 are block diagrams depicting example embodiments of aconverter-source module.

FIGS. 43A and 43B are schematic diagrams depicting example embodimentsof a components of a converter-source module mounted on one or moresubstrates.

DETAILED DESCRIPTION

Before the present subject matter is described in detail, it is to beunderstood that this disclosure is not limited to the particularembodiments described, as such may, of course, vary. It is also to beunderstood that the terminology used herein is for the purpose ofdescribing particular embodiments only, and is not intended to belimiting, since the scope of the present disclosure will be limited onlyby the appended claims.

Example embodiments of module-based energy systems are described herein,as are: example embodiments of devices, circuitry, software, andcomponents within such systems; example embodiments of methods ofoperating and using such systems; and example embodiments ofapplications (e.g., apparatuses, machines, grids, locales, structures,environments, etc.) in which such systems can be implemented orincorporated or with which such systems can be utilized. In many cases,these applications can be classified as a mobile application or astationary application.

Examples of Applications

Mobile applications are generally ones where a module-based energysystem is located on or within an entity, and stores and provideselectrical energy for conversion into motive force by a motor to move orassist in moving that entity. Examples of mobile entities with which theembodiments disclosed herein can be used include, but are not limitedto, electric and/or hybrid entities that move over or under land, overor under sea, above and out of contact with land or sea (e.g., flying orhovering in the air), or through outer space. Examples of mobileentities with which the embodiments disclosed herein can be usedinclude, but are not limited to, vehicles, trains, ships, vessels,aircraft, and spacecraft. Examples of mobile vehicles with which theembodiments disclosed herein can be used include, but are not limitedto, those having only one wheel or track, those having only two-wheelsor tracks, those having only three wheels or tracks, those having onlyfour wheels or tracks, and those having five or more wheels or tracks.Examples of mobile entities with which the embodiments disclosed hereincan be used include, but are not limited to, a car, a bus, a truck, amotorcycle, a scooter, an industrial vehicle, a mining vehicle, a flyingvehicle (e.g., a plane, a helicopter, a drone, etc.), a maritime vessel(e.g., commercial shipping vessels, ships, yachts, boats or otherwatercraft), a submarine, a locomotive or rail-based vehicle (e.g., atrain, etc.), a military vehicle, a spacecraft, and a satellite.

Stationary applications are generally applications other than mobileapplications. Generally, in stationary applications the module-basedenergy system resides in a static location while providing electricalenergy for consumption by one or more other entities. Examples ofstationary applications in or with which the embodiments disclosedherein can be used include, but are not limited to: energy systems foruse by or within one or more residential structures or locales, energysystems for use by or within one or more industrial structures orlocales, energy systems for use by or within one or more commercialstructures or locales, energy systems for use by or within one or moregovernmental structures or locales (including both military andnon-military uses), and systems that convert solar power, wind,geothermal energy, fossil fuels, or nuclear reactions into electricityfor storage. Examples of stationary applications in or with which theembodiments disclosed herein can be used include, but are not limitedto: energy systems for charging the mobile applications described above(e.g., a charging station). Other examples of stationary applications inor with which the embodiments disclosed herein can be used include, butare not limited to: a data center storage system, a power grid, or amicro-grid. A stationary energy system can be used in either a storageor non-storage role.

In describing embodiments herein, reference may be made to a particularmobile application (e.g., an electric vehicle (EV)) or stationaryapplication (e.g., grid). Such references are made for ease ofexplanation and do not mean that a particular embodiment is limited foruse to only that particular mobile or stationary application.Embodiments of systems providing power to a motor can be used in bothmobile and stationary applications. While certain configurations may bemore suitable to some applications over others, all example embodimentsdisclosed herein are capable of use in both mobile and stationaryapplications unless otherwise noted.

Example Embodiments of Module-Based Energy Systems

FIG. 1A depicts an example embodiment of a module-based energy system100. Here, system 100 includes control circuitry 102 communicativelycoupled with N converter-source modules 108-1 through 108-N, overcommunication paths or links 106-1 through 106-N, respectively. In theseembodiments, any number of two or more converter-source modules can beused (e.g., N is greater than or equal to two). The converter-sourcemodules 108, referred to herein as “ConSource” modules, can be connectedto each other in a variety of manners as will be described in moredetail with respect to FIGS. 15-29. For ease of illustration, in FIGS.1A-1C, the ConSource modules are shown connected in series, or as a onedimensional array, where the Nth ConSource module is coupled to a load101. Load 101 is the electrical load to which system 100 outputs powerwhen used to provide power. Load 101 can be any type of load including,but not limited to, a motor or a grid. For charging, the ConSourcemodules can be coupled with a charging source (not shown) either inaddition to, or instead of, load 101. As will be described in greaterdetail herein, system 100 can be configured to supply multiple loads101, including both primary and auxiliary loads.

In the embodiment of FIG. 1A, control circuitry 102 is configured tocontrol one or more ConSource modules 108 based on status informationreceived from the same or different one or more of the ConSourcemodules. Control can also be based on one or more other factors, such asrequirements of load 101. In many embodiments, the aspect that iscontrolled is the output power of each ConSource module over time;however other aspects can be controlled as an alternative to or inaddition to output power.

In many embodiments, status information of every ConSource module insystem 100 will be communicated to control circuitry 102, from whichcontrol circuitry 102 will independently control every ConSource module108-1 . . . 108-N. Other variations are possible. For example, controlof a particular ConSource module (or subset of ConSource modules) can bebased on status information of that particular ConSource module (orsubset of ConSource modules), based on status information of a differentConSource module that is not the particular ConSource module (or subsetof ConSource modules), based on status information of all ConSourcemodules other than the particular ConSource module (or subset ofConSource modules), based on status information of that particularConSource module (or subset of ConSource modules) and status informationof at least one other ConSource module that is not that particularConSource module (or subset of ConSource modules), or based on statusinformation of all ConSource modules in system 100.

As will be described herein, the status information can be informationabout one or more aspects of each ConSource module. The statusinformation can be an operating characteristic or other parameter. Typesof status information include, but are not limited to, the followingaspects of a ConSource module or components thereof: State of Charge(SOC) (e.g., the level of charge of an energy source relative to itscapacity, such as a fraction or percent), State of Health (SOH) (e.g., afigure of merit of the condition of an energy source compared to itsideal conditions), capacity, temperature, voltage, current, or thepresence of absence of a fault. Each ConSource module 108-1 . . . 108-Nincludes one or more sensors or other measuring elements for collectingsensed or measured signals or data that constitute status information,or can be converted into status information. A separate sensor is notneeded to collect each type of status information, as more than one typeof status information can be sensed or measured with a single sensor, orotherwise algorithmically determined without the need for additionalsensors.

FIG. 1B depicts another example embodiment of system 100. Here, controlcircuitry 102 is implemented as a master control device 112communicatively coupled with N different local control devices 114-1through 114-N over communication paths or links 115-1 through 115-N,respectively. Each local control device 114-1 through 114-N iscommunicatively coupled with one converter-source module 108-1 through108-N over communication paths or links 116-1 through 116-N,respectively, such that there is a 1:1 relationship between localcontrol devices 114 and converter-source modules 108.

FIG. 1C depicts another example embodiment of system 100. Here, mastercontrol device 112 is communicatively coupled with M different localcontrol devices 114-1 through 114-M over communication paths or links115-1 through 115-M, respectively. Local control devices 114 can becoupled with and control two or more converter-source modules 108. Inthe example shown here, each local control device 114 is communicativelycoupled with two converter-source modules 108, such that M local controldevices 114-1 through 114-M are coupled with 2M converter-source modules108-1 through 108-2M over communication paths or links 116-1 through116-2M, respectively.

Communication paths or links 106, 115, and 116 can each be wired orwireless communication paths or links that communicate data orinformation bidirectionally, in parallel or series fashion. Data can becommunicated in a standard or custom format. In automotive applications,communication paths or links 115 can be configured to communicate dataaccording to FlexRay or CAN protocols.

In the embodiments described with respect to FIGS. 1B and 1C, the localcontrol devices 114 receive the status information from each ConSourcemodule, or determine the status information from sensed or measuredsignals or data received from each ConSource module, and communicatethat information to master control device 112. In some embodiments localcontrol devices 114 communicate the measured or sensed data to mastercontrol device 112, which then algorithmically determines the statusinformation on the basis of that raw data. Master control device 112 canthen use the status information of the ConSource modules 108 to makecontrol determinations accordingly. The control determinations may takethe form of instructions, commands, or other information (such as amodulation index described below) that can be interpreted or utilized bylocal control devices 114 to either maintain or adjust the operation orcontribution of the ConSource modules.

For example, master control device 112 may receive status informationindicating one or more of the following conditions that a particularConSource module (or component thereof) is operating in with respect toone or more other ConSource modules in system 100: with a relativelylower SOC, with a relatively lower SOH, with a relatively lowercapacity, with a relatively lower voltage, with a relatively lowercurrent, with a relatively higher temperature, or with a fault. In suchan example, master control device 112 can output control informationthat causes the power output of that particular ConSource module to bereduced (or in some cases, raised depending on the condition). In thismanner, the power output of a ConSource module that is operating with,e.g., a higher temperature, can be reduced so as to cause thetemperature of that ConSource module to converge towards the temperatureof one or more other ConSource modules.

In other embodiments, the determination of whether to adjust theoperation of a particular ConSource module can be made by comparison ofthe status information to predetermined thresholds, limits, orconditions, and not necessarily by comparison to statuses of otherConSource modules. The predetermined thresholds, limits, or conditionscan be static thresholds, limits, or conditions, such as those set bythe manufacturer that do not change during use. The predeterminedthresholds, limits, or conditions can be dynamic thresholds, limits, orconditions, that are permitted to change, or that do change, during use.For example, master control device 112 can adjust the operation of aConSource module if the status information for that ConSource moduleindicates it to be operating in violation (e.g., above or below) of apredetermined threshold or limit, or outside of a predetermined range ofacceptable operating conditions. Similarly, master control device 112can adjust the operation of a ConSource module if the status informationfor that ConSource module indicates the presence of an actual orpotential fault (e.g., an alarm, or warning) or indicates the absence orremoval of an actual or potential fault. Examples of a fault include,but are not limited to, an actual failure of a component, a potentialfailure of a component, a short circuit or other excessive currentcondition, an open circuit, an excessive voltage condition, a failure toreceive a communication, the receipt of corrupted data, and the like.

Local control device 114 can receive, process, and transmit: the signalsfrom various sensors (e.g., temperature, voltage and current sensors) ofthe converter-source module; switching (e.g., triggering) and faultsignals to and from semiconductor switches; the voltages of elementarycells of energy storage and buffering elements; and other signals. Thelocal control device can perform communication with and transmission ofcorresponding control signals to and from the master control device 112.

In this manner, master control device 112 can control the ConSourcemodules 108 within system 100 to achieve or converge towards a desiredtarget. The target can be, for example, operation of all ConSourcemodules at the same or similar levels with respect to each other, orwithin predetermined thresholds limits, or conditions. This process isalso referred to as balancing or seeking to achieve balance in theoperation or operating characteristics of the ConSource modules. Theterm “balance” as used herein does not require absolute equality betweenConSource modules 108 or components thereof, but rather is used in abroad sense to convey to those of ordinary skill in the art thatoperation of system 100 can be used to actively reduce disparities inoperation between ConSource modules that would otherwise exist.

Referring back to FIG. 1A, control circuitry 102 can be configured tooperate and execute control using software (instructions stored inmemory that are executable by processing circuitry), hardware, or acombination thereof. Control circuitry 102 can include processingcircuitry and memory as shown here. Example implementations ofprocessing circuitry and memory are described further below.Communication path or links 106 can also include wireline power so as todirectly supply the operating power for control circuitry 102 from oneor more converter source modules 108. In certain embodiments power forcontrol circuitry 102 is supplied from only one or more converter sourcemodules 108.

Referring to FIGS. 1B-1C, master control device 112 and local controldevices 114 can similarly be configured to operate and execute controlusing software (instructions stored in memory that are executable byprocessing circuitry), hardware, or a combination thereof, and each caninclude processing circuitry and memory as shown here. Exampleimplementations of processing circuitry 120 and memory 122 are describedfurther below. Communication path or links 116 can also include wirelinepower so as to directly supply the operating power for local controldevices 114 from one or more converter source modules 108. In certainembodiments, the operating power for each local control device 114 issupplied only by the one or more converter source modules 108 to whichthat local control device 114 is connected by path 116. The operatingpower for the master control device 112 can be supplied indirectly fromone or more of the converter-source modules 108 (e.g., such as through acar's power network).

In some embodiments, control circuitry 102 can include a single controldevice for the entire system 100. In other embodiments, controlcircuitry can be distributed between local control devices 114associated with the modules 108, such that a separate master controldevice 112 is not necessary and can be omitted from system 100.

In some embodiments, control of system 100 can be distributed betweencontrol circuitry 102 dedicated to or local to system 100, and controlcircuitry that is shared with other parts of the application. Forexample, in an automotive application, master control device 112 can beimplemented as part of another control device (e.g., Electronic ControlUnit (ECU)) of the vehicle having responsibility for one or more otherautomotive functions (e.g., motor control, driver interface control,traction control, etc.).

Control circuitry 102 can have a communicative interface forcommunicating with another control device of the application. Forexample, in an automotive application, control circuitry 102 (e.g.,master control device 112) can output data or information about system100 to another control device (e.g., the ECU) of the vehicle.

Example Embodiments of Converter-Source Modules within Module-BasedSystems

FIGS. 2-4 depict example embodiments of converter-source modules 108, orConSource modules, within system 100 as depicted in FIG. 1B, with onelocal control device 114 per ConSource module. The embodiments of FIGS.2-4 and any and all other embodiments described herein can beimplemented in accordance with the configurations of FIGS. 1A-1C unlessotherwise noted.

ConSource modules 108 can be implemented as voltage converters orcurrent converters. For ease of description, the embodiments describedherein are done so with reference to voltage converters, although theembodiments are not limited to such.

FIG. 2 is a block diagram depicting an example embodiment of a ConSourcemodule 108A within system 100. This embodiment of ConSource module 108Amay be referred to herein as version 1 of an example ConSource module(ConSource V1) and is an example of a type of converter-source module108. Also shown is a local control device 114 (LCD) and a master controldevice 112 (MCD). ConSource V1 108A is communicatively coupled with theLCD 114, which in turn is communicatively coupled with the MCD 112.

The ConSource V1 108A includes an energy source 202 (Energy Source 1),which can include one or more energy storage elements. Energy Source 1can be, for example, one of the following, but not limited to, anultra-capacitor 600 (FIG. 6A), a battery module 610 including at leastone cell or multiple battery cells connected in series and/or inparallel (FIG. 6B), or fuel, a fuel-cell, or fuel cell module 620 (FIG.6C).

The outputs out1 and out2 of Energy Source 1 can be connected to inputterminals in1 and in2 of an Energy Buffer, respectively, which caninclude, for example, one of the following, but not limited to, elementsand topologies based on: an electrolytic and/or film capacitor CEB 700(FIG. 7A), a Z-source network 710, formed by two inductors LEB1 and LEB2and two electrolytic and/or film capacitors CEB1 and CEB2 (FIG. 7B), aQuasi Z-source network 720, formed by two inductors LEB1 and LEB2, twoelectrolytic and/or film capacitors CEB1 and CEB2 and a diode DEB (FIG.7C). A choice of specific topology and components of Energy Bufferdepends on a maximum permissible amplitude of high frequency voltagepulsations on output terminals out1 and out 2 of the Energy Buffer.These pulsations can degrade the performance of the ConSource module108, thus they can be efficiently buffered by designing suitableelements and topologies as a basis thereof.

The outputs out1 and out2 of the Energy Buffer are connectedrespectively to the inputs in1 and in2 of a Converter V1. A schematicrepresentation of an example embodiment of a converter V1 206 is shownin FIG. 5A. In many embodiments, the Converter V1 206 can include atleast four switches S3, S4, S5, S6, which can be configured assemiconductor switches, such as metal-oxide-semiconductor field-effecttransistors or MOSFETs (as shown in FIG. 4). Another switch example isan insulated-gate bipolar transistor or IGBT. Semiconductor switches canbe operated at relatively high switching frequencies, thereby permittingthe Converter V1 to be operated in pulse-width modulated mode ifdesired, and to respond to control commands within a relatively shortinterval of time. This can provide a high tolerance of output voltageregulation and fast dynamic behavior in transient modes.

In this embodiment, Converter V1 206 generates three different voltageoutputs, +VDCL, 0, and −VDCL by connecting the DC line voltage VDCL,between its terminals in1 and in2, to its output terminals out1 and out2by different combinations of switches S3, S4, S5, S6. To obtain +VDCL,switches S3 and S6 are turned on, whereas −VDCL can be obtained byturning on the switches S4 and S5. By turning on S3 and S5 or S4 and S6,the output voltage is set to zero or a reference voltage.

The control switching signals for semiconductor switches S3, S4, S5, S6may be generated in different ways depending on the flexibility andrequirements of the adopted control technique in the LCD and MCD (shownin FIG. 2). One approach is to use space vector pulse-width modulationSVPWM or sinusoidal pulse-width modulation SPWM, or variations thereof,to generate the output voltage of Converter V1. An example of an outputvoltage waveform 900 of a Converter V1 is shown in FIG. 9. Themodulation method also depends on which version of system 100 to whichit is applied and one possible solution of modulation will be presentedherein further as an example.

In some embodiments using pulse width modulation, the LCD (and not theMCD) generates the switching signals for the switches in the ConSourcemodule. In some embodiments, such as those using hysteresis, generationof the switching signals can be performed by the MCD. The LCD 114 shownin FIG. 2 can be connected to ConSource V1 108A via a set ofdiagnostics, measurement, protection and control signal lines, and canperform one or more of three primary functions. The first function ismanagement of Energy Source 1. The second function is protection of theEnergy Buffer and more specifically it's components from over-current,over-voltage and high temperature conditions. The third function iscontrol and protection of Converter V1 206.

In one example embodiment, the function of management, by the LCD 114,of Energy Source 1 for ConSource V1 module 108A is as follows. The LCD114 accepts the measurement signals VES1, TES1, IES1, which are:VES1—the voltages of at least one of the, preferably all, elementarycomponents of Energy Source 1 or the voltages of groups of elementarycomponents, such as, for example and not limited to, battery cells(individual or connected in series and/or in parallel), ultra-capacitorcells (individual, or connected in series and/or in parallel); TES1—thetemperatures of at least one of, preferably all, elementary componentsof Energy Source 1 or the temperatures of groups of elementarycomponents; IES1—the output current of Energy Source 1. Based on thesemeasurement signals the LCD 114 can perform one or more of thefollowing: calculation or determination of a real capacity, actual Stateof Charge (SOC) and State of Health (SOH) of the elementary componentsor groups of elementary components; set a warning or alarm signal, basedon measured and/or calculated data; and/or transmission of correspondingsignals to the MCD 112.

In one example embodiment, the function of protection, by the LCD, ofthe Energy Buffer 204 for ConSource V1 module 108A is as follows. TheLCD 114 accepts the measurement signals VEB, TEB, IEB, which are:VEB—the voltages of at least one major component of the Energy Buffer,for example and not limited to, capacitor CEB, or capacitors CEB1, CEB2(see FIGS. 7A-7C); TEB—the temperature of at least one component of theEnergy Buffer; and/or IEB—the current through at least one component ofthe Energy Buffer. Based on these measurement signals, the LCD 114 canperform the following: setting of a warning or alarm signal based onmeasured data; and/or transmission of corresponding warning or alarmsignals to the MCD 112.

In one example embodiment, the function of control and protection, bythe LCD 114, of the Converter V1 206 for ConSource V1 module 108A is asfollows. The LCD can receive the command signals from the MCD (e.g.,over FlexRay or CAN), which in some embodiments can be a modulationreference signal and an enable signal, or a reference signal and amodulation index, which can be used with a pulse width modulationtechnique in the LCD to generate the control signals for semiconductorswitches S3, S4, S5, S6. The current feedback signal IOUT (not shown inFIG. 2) coming from an integrated current sensor of Converter V1 206 canbe used for overcurrent protection together with one or more signals F,coming from driver circuits (not shown in FIG. 2) of the switches ofConverter V1 206, which can carry information about failure statuses(e.g., short circuit or open circuit failure modes) of all switches inConverter V1. Based on this data, the LCD can make a decision on whichcombination of switching signals to be applied to correspondingsemiconductor switches S3, S4, S5, S6 to bypass or to disconnect theConverter V1 and the entire ConSource V1 module 108A from system 100. (Aswitching signals for a particular switch can turn that switch on oroff.)

FIG. 3 is a block diagram depicting another example embodiment of aConSource module 108B that may be referred to herein as version 2 of theConSource module (ConSource V2) and is an example of a type ofconverter-source module 108. ConSource V2 108B is communicativelycoupled with the LCD114, which in turn is communicatively coupled withthe MCD 112.

In this embodiment, the ConSource V2 108B is in a dual energy sourceconfiguration with a primary Energy Source 1 202 and secondary EnergySource 2 304. Energy Source 1 can include, for example, one of thefollowing, but not limited to, an ultra-capacitor or super-capacitor 600(FIG. 6A), a battery module 610 (FIG. 6B) including at least one cell orplurality of battery cells connected in series and/or in parallel, andfuel, a fuel-cell, or a fuel-cell module 620 (FIG. 6C).

The outputs out1 and out2 of Energy Source 1 202 can be connected toinput terminals in1 and in2 of an Energy Buffer 204, respectively, whichcan include, for example, one of the following, but not limited to,elements and topologies based on: an electrolytic and/or a filmcapacitor CEB 700 (FIG. 7A), a Z-source network 710, formed by twoinductors LEB1 and LEB2 and two electrolytic and/or film capacitors CEB1and CEB2 (FIG. 7B), a Quasi Z-source network 720, formed by twoinductors LEB1 and LEB2, two electrolytic and/or film capacitors CEB1and CEB2 and a diode DEB (FIG. 7C). The outputs out1 and out2 of EnergyBuffer 204 are connected respectively to the inputs in1 and in3 ofConverter V2 308.

The output out2 of the Energy Buffer 204 can be connected also to theoutput out2 of Energy Source 2 304. Another output of Energy Source 2,out1, is connected to input in2 of Converter V2 308. The Energy Source 2can include, for example, one of the following, but not limited to,storage elements such as: an electrolytic and/or a film capacitor CEB800 (FIG. 8A); an ultra-capacitor or a super-capacitor 810 (FIG. 8B); abattery module 820 including at least one cell or plurality of batterycells connected in series and/or in parallel (FIG. 8C); an electrolyticand/or a film capacitor CEB 800 connected in parallel with anultra-capacitor or super-capacitor 810 (FIG. 8D); an electrolytic and/ora film capacitor CEB 800 connected in parallel with battery module 820,including at least one cell or plurality of battery cells connected inseries and/or in parallel (FIG. 8E); an electrolytic and/or a filmcapacitor CEB 800 connected in parallel with an ultra-capacitor (orsuper-capacitor) 810 and a battery module 820, including at least onecell or plurality of battery cells connected in series and/or inparallel (FIG. 8F).

A simplified schematic representation of example embodiment of aConverter V2 308 is shown in FIG. 5B. Here, the Converter V2 308includes six switches S1, S2, S3, S4, S5, S6, which can be configured assemiconductor switches, such as e.g. MOSFETs (as shown in FIG. 5B) orIGBTs. Semiconductor switches can be operated at high switchingfrequency, thereby permitting the Converter V2 308 to be operated inpulse-width modulated mode if required, and to respond to the controlcommands within a short interval of time, providing a high tolerance ofoutput voltages regulation and fast dynamic behavior in transient modes.

The left-hand side of the Converter V2 308 includes two switches S1 andS2, and can generate two different voltages at Node 1, which are +VDCLand 0, referenced to input In3, which can be at virtual zero potential.The coupling inductor L_(C) is connected between input In3 and Node 1.The output out1 of Energy Source 2 is connected to coupling inductor LCat the input In 3 of Converter V2 308. The current consumed from orgenerated to Energy Source 2 304 can be controlled by regulating thevoltage on coupling inductor L_(C), using, for example, a pulse-widthmodulation technique or a hysteresis control method for commutatingswitches S1 and S2. Other techniques can be used as well.

The right-hand side of Converter V2 308 includes four switches S3, S4,S5, S6, and is capable of generating three different voltage outputs,+VDCL, 0, and −VDCL by connecting the DCL-voltage VDCL between terminalsin1 and in2 to the output terminals out1 and out2 by differentcombinations of switches S3, S4, S5, S6. To obtain +VDCL voltage betweenout1 and out2, switches S3 and S6 are turned on, whereas −VDCL voltagebetween out1 and out2 can be obtained by turning on switches S4 and S5.By turning on S3 and S5 or S4 and S6, the output voltage is set to zeroor a reference potential.

The control switching signals for semiconductor switches S3, S4, S5, S6may be generated in different ways depending on the flexibility andrequirements of the adopted control technique in the LCD 114 and the MCD112. One approach is to use pulse width modulation, such as space vectorpulse-width modulation (SVPWM) or sinusoidal pulse-width modulation(SPWM), including additional variations of thereof, to generate theoutput voltage of Converter V2. A typical output voltage waveform 900 ofConverter V2 308 is shown in FIG. 9. The modulation method also dependson which version of ACi-battery pack it is applied to and one possiblesolution of modulation will be presented further as an example.

In this example ConSource V2 module 108B, Energy Source 1 202 acts as aprimary energy source and therefore supplies the average power needed bythe load. Energy Source 2 304 can be a secondary energy source with thefunction of assisting Energy Source 1 by providing additional power atload power peaks, or absorbing excess power.

FIG. 10 shows the output voltage waveform 1000 from an examplemodule-based energy storage system having six example converter-sourcemodules.

FIG. 11 is a block diagram depicting an example embodiment of power flowmanagement 1100 between two Energy Sources (Energy Source 1 202 andEnergy Source 2 304) and a load for an example embodiment of a ConSourceV2 module 108B. The load can be, for example, but not limited to, asingle phase of an electric vehicle motor or an electrical grid. Thisembodiment allows a complete decoupling between the electricalcharacteristics (terminal voltage and current) of each energy source andthose of the load 1102.

In these embodiments, Power Flow Controller 1 1110 and Power FlowController 2 1120 can be discrete control devices, separate from the LCD114 and MCD 112, can be implemented as software within the LCD, can beimplemented as hardware within the LCD, or can be implemented as acombination of hardware and software within the LCD. In someembodiments, the functions of Power Flow Controller 1 1110 and PowerFlow Controller 2 1120 can be shared or distributed between the LCD 114and MCD 112.

Power Flow Controller 1 1110 can receive a signal of reference powerflow of Energy Source 1 (P_(ES1, REF)) from the LCD 114. This signal canbe determined by a main Power Management Controller located in the MCD112 based on motor power or electrical grid power requirements and astatus of Energy Source 1 202 of the ConSource V2 module 108B. PowerFlow Controller 1 1110 can estimate a maximum allowable charge and/ordischarge current of Energy Source 1 202 and calculate a realpermissible power flow (P_(ES1)) of Energy Source 1. This value can becompared with P_(CONSOURCE) and the difference can be applied to PowerFlow Controller 2 1120 as a signal (P_(ES2, REF)). Power Flow Controller2 1120 can calculate the reference current in coupling inductor L_(C)based on the voltage between output terminals out1 and out2 of EnergySource 2 304 and determines the switching signals for switches S1 and S2of Converter V2 308, using, for example, but not limited to pulse-widthmodulation or hysteresis control algorithms. Thus, the total power flow(P_(CONSOURCE)) can be provided by the switching portion of Converter V2that includes switches S3, S4, S5, S6. The power flow of Energy Source 1202 (P_(ES1)) can be estimated based on a maximum permissible current ofEnergy Source 1 and actual conditions of Energy Source 1, such as, butnot limited to, State of Charge (SOC), State of Health (SOH),temperature of elementary cells or a group of parallel and/or seriesconnected cells, equivalent series resistance, and the like. The powerflow (P_(ES1)) can be maintained as a difference between current valuesof the load (P_(LOAD)) and energy source 2 (P_(ES2)), where P_(ES2) ismanaged by the switching portion of Converter V2 308 that includesswitches S1, S2 and the coupling inductor LC.

In many embodiments, Energy Source 2 304 can be a secondary energysource and its function is to assist Energy Source 1 by providing powerat load power peaks and/or absorbing excess power. A secondary functionof Energy Source 2 304 can be active filtering, such as to reduce(attenuate) or eliminate any second-order current harmonic that appearsin the current IDC_CONV flowing at the inputs in1 and in3 of theConverter V2 as a result of, e.g., the intrinsic pulsating power natureof a single-phase system. This harmonic can have a considerablepeak-to-peak value, which can reach up to two times the load currentamplitude. The second-order current component exhibits somedisadvantages, e.g., increase of the inner losses in the Energy Source 1202 related to the resulting current RMS value. To perform thissecondary function, Energy Source 2 304 can include an electrolyticcapacitor or an ultra-capacitor (or super-capacitor) as standalonecomponents, or connected in parallel with other energy storage elementsas shown in FIGS. 8A, 8B, and 8D-8F.

FIGS. 12A and 12B show examples of waveforms 1200, 1220 occurring beforeand during performance this active filtering secondary function. Beforethe compensations starts (before time moment t₁), the current of EnergySource 1 202 (FIG. 12A) includes a DC-component (IDC=130 A) and a secondorder harmonic component with an amplitude I2AC=60 A. The high frequencyharmonics (not shown) that are determined by the switching behavior ofConverter V2 308 are efficiently buffered by the Energy Buffer 204.Starting from the time moment t₁, the Converter V2 starts generatingcurrent I_(ES2), redirecting the second order harmonic of currentI_(ES1) to Energy Source 2. This current I_(ES2) has an amplitude ofmain harmonic equal to that of the second order harmonic of I_(ES1)current, but with nearly opposite phase angle, in such a way that theresulting current in Energy Source 1 I_(ES1) includes eitherDC-component only or mostly DC-component with some significantly reducedAC-ripples, as shown in FIG. 12A. In a case where only the secondaryfunction is performed by Converter V2, and if the Energy Source 2includes only a capacitor and/or a super-capacitor 810, the currentI_(ES2) (FIG. 12B) may include a DC component which is needed to besupplied from the load or from Energy Source 1 202 to maintain thevoltage on the capacitor and/or the super-capacitor 810 of Energy Source2 304 at set value, which is required for correct operation of ConverterV2 308.

Both primary and secondary functions performed by Converter V2 anddescribed above can be performed either separately or at the same time.If at the same time, the Energy Source 2 304 preferably includes anelectrolytic capacitor or ultra-capacitor 810 connected in parallel withother energy storage elements as shown in FIGS. 8A, 8B, and 8D-8F.

The LCD 114 for ConSource V2 module is shown in FIG. 3 connected toConSource V2 module 108B via a set of diagnostics, measurement,protection and control signal lines, and can perform at least one of,preferably all of, four major functions. The first function ismanagement of Energy Source 1 202. The second function is management ofEnergy Source 2 304. The third function is protection of the EnergyBuffer 204 and more specifically its components from over-current,over-voltage and high temperature. The fourth function is control andprotection of Converter V2 308.

The function of management of Energy Source 1 for ConSource V2 module108B can be as follows. The LCD 114 accepts the measurement signalsVES1, TES1, IES1, which are: VES1—the voltages of all elementarycomponents/cells of Energy Source 1 or the voltages of groups ofelementary components/cells, such as, for example, but not limited to,battery cells, individual or connected in series and/or in parallel,ultra-capacitor cells, individual, or connected in series and/or inparallel; TES1—the temperatures of all elementary components of EnergySource 1 or the temperatures of groups of elementary components;IES1—the output current of Energy Source 1. Based on these measurementsignals LCD can perform the following: calculates a real capacity,actual State of Charge (SOC) and State of Health (SOH) of the elementarycomponents or groups of elementary components; set a warning or alarmsignal based on measured and calculated data; transmission ofcorresponding signals to the MCD 112.

The function of management of Energy Source 2 304 for ConSource V2module 108B can be as follows. The LCD 114 can receive the measurementsignals VES2, TES2, IES2, which are: VES2—the voltages of all elementarycomponents or cells of Energy Source 2 or the voltages of groups ofelementary components or cells, such as, for example and not limited to,battery cells, individually or connected in series and/or in parallel,ultra-capacitor cells, individually or connected in series and/or inparallel; TES2—the temperatures of all elementary components of EnergySource 2 or the temperatures of groups of elementary components;IES2—the output current of Energy Source 2. Based on these measurementsignals, the LCD can perform the following: calculates a real capacity,actual State of Charge (SOC) and State of Health (SOH) of the elementarycomponents or groups of elementary components; set a warning or alarmsignal, based on measured and calculated data; and/or communicatedcorresponding signals to the MCD.

The function of protection of Energy Buffer for ConSource V2 module 108Bcan be as follows. The LCD 114 receives the measurement signals VEB,TEB, IEB, which are: VEB—the voltages of at least one major component ofEnergy Buffer, for example and not limited to, capacitor CEB, orcapacitors CEB1, CEB2 (see FIGS. 7A-7C); TEB—the temperature of at leastone major components of Energy Buffer; and/or IEB—the current through atleast one major components of Energy Buffer. Based on these measurementsignals LCD can perform the following: set a fault (e.g., warning oralarm) signal based on measured data; and/or transmit correspondingfault signals to the MCD 112.

The function of control and protection of Converter V2 308 for ConSourceV2 module 108B can be as follows. The LCD 114 receives the commandsignals from the MCD 112, which can be a modulation reference signal andenable signal, or a reference signal and a modulation index, which canbe used in a PWM and/or a Hysteresis function in the LCD to generate thecontrol signals for semiconductor switches S1, S2, S3, S4, S5, S6 inaccordance to power management and/or second order harmonic reductiontechniques described above. The current feedback signals IES2, IOUTcoming from the integrated current sensors (not shown in FIG. 3) ofConverter V2 can be used for overcurrent protection together withsignals F, for example, coming from driver circuits (not shown in FIG.3), of semiconductor devices of Converter V2 308, which carry theinformation about failure statuses (e.g., short circuit or open circuitfailure mode) of one or more, preferably all, of the semiconductorswitches. Based on this specific data, the LCD 114 can make a decisionon which combination of switching signals S1, S2, S3, S4, S5, S6 to beapplied to the corresponding semiconductor switches to bypass ordisconnect the Converter V2 and the entire ConSource V2 module fromsystem 100 (e.g., the battery pack, etc.).

FIG. 4 is a block diagram depicting an example embodiment of a ConSourcemodule 108C, referred to as version 3 of the ConSource module (ConSourceV3) and is an example of a type of converter-source module 108.ConSource V3 108C is communicatively coupled with the LCD 114, which inturn is communicatively coupled with the MCD 114.

The ConSource V3 module 108C can include an energy source Energy Source1 202 and Converter V2 308 with an additional input for connection of anAuxiliary Load 2 410, if desired, as shown in FIG. 4. The ConSource V3module 108C has output ports 1 and 2 for connection with other ConSource(e.g., V1/V2/V3) modules within an example system 100. The illustratedoutput ports 3 and 4 of ConSource V3 are used for connection of theexample ConSource V3 module to the same output ports of other ConSourceV3 modules of an example system 100, if needed, and/or for connection toan Auxiliary Load 1 408, if desired, as shown in FIG. 4. The illustratedoutput ports 5 and 6 of ConSource V3 108C are used for connection of theexample ConSource V3 module to the same output ports of other ConSourceV3 modules of an example system 100, if needed, and/or for connection toan Auxiliary Load 2 410, if desired, as shown in FIG. 4.

Energy Source 1 can include, for example, one of the following, but notlimited to, storage elements according to FIG. 6: an ultra-capacitor orsuper-capacitor 600 (FIG. 6A), a battery module 610 including at leastone cell or plurality of battery cells connected in series and/or inparallel (FIG. 6B), and fuel, a fuel-cell, or a fuel-cell module 620(FIG. 6C).

The outputs out1 and out2 of Energy Source 1 202 are connected to inputterminals in1 and in2 of the Energy Buffer 204, respectively, which caninclude, for example, one of the following, but not limited to, elementsand topologies based on: an electrolytic and/or a film capacitor CEB 700(FIG. 7A), a Z-source network 710, formed by two inductors LEB1 and LEB2and two electrolytic and/or film capacitors CEB1 and CEB2 (FIG. 7B), aQuasi Z-source network 720, formed by two inductors LEB1 and LEB2, twoelectrolytic and/or film capacitors CEB1 and CEB2 and a diode DEB (FIG.7C). The outputs out1 and out2 of Energy Buffer 204 are connectedrespectively to the inputs in1 and in3 of Converter V2 308.

A simplified schematic representation of Converter V2 308 is shown inFIG. 5B. The Converter V2 includes six switches S1, S2, S3, S4, S5, S6,which can be configured as semiconductor switches, such as e.g. MOSFETs(as shown in FIG. 5B), JFETs or IGBTs. The left-hand side of theConverter V2 includes two switches S1 and S2 that can generate twodifferent voltages at Node 1, which are +VDCL and 0, referenced to inputIn3, which is at virtual zero potential. The coupling inductor L_(C) isconnected between input In3 and Node 1. The output of coupling inductorL_(C) is connected through input In2 of Converter V2 308 to port 5 ofConSource V3 module 108C and to optional Auxiliary Load 2 410 as shownin FIG. 4. It is assumed that Auxiliary Load 2 has an input capacitor,so the Converter V2 308 can regulate and stabilize the required constantvoltage on the load regulating the voltage on and current throughcoupling inductor LC.

The right-hand side of the Converter V2 308 includes four switches S3,S4, S5, S6, and can generate three different voltage outputs, +VDCL, 0,and −VDCL by connecting the DCL-voltage VDCL between terminals in1 andin2 to the output terminals out1 and out2 by different combinations ofswitches S3, S4, S5, S6. To obtain +VDCL voltage between out1 and out2,switches S3 and S6 are turned on, whereas −VDCL voltage between out1 andout2 can be obtained by turning on switches S4 and S5. By turning on S3and S5 or S4 and S6, the output voltage is set to zero or a referencepotential.

The control switching signals for semiconductor switches S3, S4, S5, S6may be generated in different ways depending on the flexibility andrequirements of the adopted control technique in the LCD 114 and the MCD112.

Energy Source 1 202 can supply the corresponding part of power needed bythe load of system 100, Auxiliary Load 1 408 and/or Auxiliary Load 2410, if connected. FIG. 13 shows an example of power flow management fora ConSource V3 module, where power flow between Energy Source 1,Auxiliary Load 1, and Auxiliary Load 2 can be adjusted. Examples ofauxiliary loads can be, for example, an on-board electrical network ofan electric vehicle, an HVAC system of an electric vehicle. The load ofsystem 100 can be, for example, one of the phases of the electricvehicle motor or electrical grid. This embodiment can allow a completedecoupling between the electrical characteristics (terminal voltage andcurrent) of the energy source and those of the loads.

In these embodiments, referring to FIG. 13, Power Flow Controller 1 1310(PFC 1), Power Flow Controller 2 1320 (PFC 2), Power Flow Estimator 1(PFE 1), and Power Flow Estimator 2 (PFE 2) can be discrete controldevices, separate from the LCD 114 and MCD 112, can be implemented assoftware within the LCD, can be implemented as hardware within the LCD,or can be implemented as a combination of hardware and software withinthe LCD. In some embodiments, the functions of PFC 1, PFC 2, PFE 1, andPFE 2 can be shared or distributed between the LCD and MCD.

PFE 1 can receive a signal of reference power flow of Energy Source 1202 P_(ES1, REF) from the LCD 114. This signal can be determined by amain Power Management Controller located in the MCD 112 based on loadpower requirements and status of Energy Source 1 of this specificConSource V3 module 108C. PFE1 can also receive the signal P_(LOAD1),determined by power consumption and/or generation of Auxiliary Load 1408 and obtained in power calculation block (not shown in FIG. 13),based on the current in Auxiliary Load 1 (e.g., measured by a currentsensor which can be integrated in ConSource V3 module or received by theLCD directly from Auxiliary Load 1). The total reference power flow forEnergy Source 1 202 P_(TOT_REF_ES1) can be a sum of P_(ES1, REF) andP_(LOAD1). PFC 1 1310 can estimate a maximum allowable charge and/ordischarge current of Energy Source 1 and calculate a real permissiblepower flow P_(TOT,ES1) of Energy Source 1.

PFE 2 1320 can receive a signal of total power flow of Energy Source 1P_(TOT,ES1) from PFC 1. PFE2 can receive also the signal P_(LOAD2),determined by power consumption and/or generation of Auxiliary Load 2and obtained in a power calculation block (not shown in FIG. 13), basedon the current in Auxiliary Load 2 (e.g., measured by a current sensor,which can be integrated in ConSource V3 module or received by the LCDdirectly from Auxiliary Load 2). The total reference power flow forConSource V3 module with two Auxiliary loads P_(CONSOURCE) can be thesum of P_(LOAD2) and P_(TOT,ES1). The total P_(CONSOURCE) power flow isprovided by the switching portion of the Converter V2, which includesswitches S3, S4, S5, S6. The power flow P_(LOAD2) can be managed by theswitching portion of Converter V2 that includes switches S1, S2 andcoupling inductor L_(C).

The LCD 114 for ConSource V3 module 180C is shown in FIG. 4. It can beconnected to ConSource V2 module 108B via a set of diagnostics,measurement, protection and control signal lines, and can perform atleast one of, preferably all of, four major functions. The firstfunction can be management of Energy Source 1 202. The second functioncan be management of Auxiliary Load 2 410. The third function can beprotection of the Energy Buffer 204 and more specifically its componentsfrom over-current, over-voltage and high temperature. The fourthfunction can be control and protection of Converter V1.

In some example embodiments, the function of management of Energy Source1 202 for ConSource V3 module 108C can be as follows. The LCD 114accepts the measurement signals VES1, TES1, IES1, which are: VES1—thevoltages of all elementary components/cells of Energy Source 1 202 orthe voltages of groups of elementary components/cells, such as, forexample, but not limited to, battery cells, individual or connected inseries and/or in parallel, ultra-capacitor cells, individual, orconnected in series and/or in parallel; TES1—the temperatures of allelementary components of Energy Source 1 or the temperatures of groupsof elementary components; IES1—the output current of Energy Source 1.Based on these measurement signals LCD can perform the following:calculates a real capacity, actual State of Charge (SOC) and State ofHealth (SOH) of the elementary components or groups of elementarycomponents; set a warning or alarm signal based on measured andcalculated data; transmission of corresponding signals to the MCD.

The function of management of Auxiliary Load 2 410 for ConSource V3module 108C can be as follows. The LCD receives the measurement signalsVAL2, IAL2, which are: VAL2—the voltage between ports 5 and 6 ofConSource V3 module, and IAL2—the current in coupling inductor LC ofConverter V2, which is a current of Auxiliary Load 2. Based on thesesignals the LCD performs a correction of the reference signal for pulsewidth modulation in the LCD to stabilize and/or to control the voltageon Auxiliary Load 2.

The function of protection of Energy Buffer 204 for ConSource V3 module108C can be as follows. The LCD can receive the measurement signals VEB,TEB, IEB, which are: VEB—the voltages of at least one major component ofEnergy Buffer, for example and not limited to, capacitor CEB, orcapacitors CEB1, CEB2 (see FIGS. 7A-7C); TEB—the temperature of at leastone major components of Energy Buffer; IEB—the current through at leastone major components of Energy Buffer. Based on these measurementsignals LCD can perform the following: set a fault (e.g., warning oralarm) signal based on measured data; and/or transmit correspondingfault signals to the MCD.

The function of control and protection of Converter V2 308 for ConSourceV3 module 108C can be as follows. The LCD 114 receives the commandsignals from the MCD 112, which can be a modulation reference signal andenable signal, or a reference signal and a modulation index, which canbe used in a PWM and/or a Hysteresis function in the LCD to generate thecontrol signals for semiconductor switches S1, S2, S3, S4, S5, S6 inaccordance to power management and/or second order harmonic reductiontechniques described above. The current feedback signals IES2, IOUTcoming from integrated current sensors of Converter V2 (not shown inFIG. 4) can be used for overcurrent protection together with one or moresignals F, coming from driver circuits (not shown in FIG. 4), ofsemiconductor devices of Converter V2, which carry the information aboutfailure statuses (e.g., short circuit or open circuit failure mode) ofone or more, preferably all, of the semiconductor switches. Based onthis specific data, the LCD can make a decision on which combination ofswitching signals S1, S2, S3, S4, S5, S6 to be applied to thecorresponding semiconductor switches to bypass or disconnect theConverter V2 308 and the entire ConSource V3 module from system 100(e.g., the battery pack, etc.).

One example of a ConSource module is a converter-battery module having abattery as the first energy source. A converter-battery module can bereferred to as a ConBatt module. A ConBatt module can be used in, e.g.,a battery pack of a mobile application such as an electric vehicle (EV).System 100, configured for use as a battery pack with a plurality ofConBatt modules, can be referred to as a ConBatt pack.

In other example embodiments, the ConSource modules can connect withadditional sources of electrical power, such as photovoltaic panelsand/or a wireless charging receiver. In other example embodiments,system 100 can connect to another system 100 (e.g., another ConBattpack) coupled with other auxiliary loads of different voltage levels,such as, e.g., an EV's on-board electrical network system andair-conditioner.

Example Embodiments of Module Arrangements for Module-Based Systems

FIGS. 15-29 depict example embodiments of system 100 arranged accordingto various architectures or configurations. In these embodiments system100 is referred to as a ConSource pack, although the embodiments are notlimited to packs. For ease of illustration, the MCD and the LCDs in eachembodiment are not shown. As can be seen, the modules can be arranged innumerous ways such that the power contributed by each module can besummed to form one or more of, e.g., a single phase AC output, multiplephases of AC outputs, and a DC output.

FIG. 15 shows an example embodiment of a ConSource pack 1500 including aone-dimensional array of N number of interconnected ConSource modules108-1, 108-2 . . . 108-N according to the present disclosure. Each ofthe ConSource modules in the array may be configured according to anyone of the three module versions (V1, V2 and V3) discussed above withregard to FIGS. 2, 3 and 4. The plurality of ConSource modules mayinclude modules configured according to the same module version (V1, V2or V3) or a mixture of modules configured according to two or more ofthe three module versions (V1, V2 and V3). A first port 1 of anConSource V1/V2/V3 module of a first row of the one-dimensional array(“first ConSource V1/V2/V3 module”) is connected to a first outputterminal out1 of the one-dimensional array of ConSource modules. Asecond port 2 of the first ConSource V1/V2/V3 module is connected to afirst port 1 of a ConSource V1/V2/V3 module in a second row (“secondConSource V1/V2/V3 module”). A second port 2 of the second ConSourceV1/V2/V3 module is connected to a first port of ConSource V1/V2/V3module in a third row (“third ConSource V1/V2/V3 module”) and so on inthe same order further down to a Nth ConSource V1/V2/V3 module in an Nthor last row. A second port 2 of the Nth ConSource V1/V2/V3 module isconnected to a second output terminal out 2 of the one-dimensional array1500. This one-dimensional array of N number of interconnected ConSourcemodules can be used as a DC or single phase AC energy source, such as,e.g., a battery pack, for stationary energy storage applications for DCor AC single-phase loads. A DC or AC single-phase load can be connectedbetween the first and second output terminals out1 and out2.

The output voltage of the one-dimensional array of N number ofinterconnected ConSource modules can be generated using, for example,but not limited to, space vector modulation or sine pulse widthmodulation (“PWM”) with a Phase Shifted Carrier technique. The switchingsignals for each of the ConSource modules' Converter may then begenerated using Phase Shifted Carrier technique. This technique ensuresthat the ConSource modules are continuously rotated and the power isalmost equally distributed among them.

The principle of a phase shifted technique is to generate a multileveloutput PWM waveform using incrementally shifted two-level waveforms.Therefore an N-level PWM waveform is created by the summation of N−1two-level PWM waveforms. These two-level waveforms are generated bycomparing the reference waveform to triangular carriers 1400, 1410(FIGS. 14A, 14B) that are incrementally shifted by 360°/(N−1). A 9-levelexample 1400 is shown in FIG. 14A. The carriers are incrementallyshifted by 360°/(9−1)=45° and compared to the reference waveform. Theresulted two-level PWM waveforms 1420 are shown in FIG. 14C. Thesetwo-level waveforms may be used as the switching signals forsemiconductor switches of the Converters in each ConSource module 108.As an example, for a one-dimensional array including four interconnectedConSource modules, each having a Converter V1, the 0° signal is used forS3 and 180° signal for S6 of the first ConSource module, the 45° signalis used for S3 and 225° signal for S6 of the second ConSource module,and so on. Note that in all Converter V1 s, the signal for S3 iscomplementary to S4 and the signal for S5 is complementary to S6 alongwith certain dead-time to avoid shoot through of each leg. FIG. 14Ddepicts an example AC waveform 1430 produced by superposition of outputvoltages from the four modules.

This one-dimensional array 1500 embodiment of system 100 shown in FIG.15 enables obtaining a high voltage of any shape with very low totalharmonic distortion between first and second terminals out 1 and out 2using low and/or medium voltage rated energy source elements andswitching components (MOSFETs, JFETs, IGBTS, etc.) with significantlyreduced switching and conduction losses in the ConSource modules.

FIG. 16 shows an example embodiment of a first version of a ConSourcepack including a two-dimensional array 1600 or two one-dimensionalarrays 1500 of N number of interconnected ConSource V1/V2/V3 modules108-1, 108-2 . . . 108-N according to the present disclosure. Aprinciple of configuration and output of DC or AC voltage generation ofeach of the two one-dimensional arrays 1500, which form thistwo-dimensional array 1600, is described above with regard to FIG. 15. Asecond port 2 of each of an Nth ConSource V1/V2/V3 module in Nth or lastrows of both of the one-dimensional arrays are connected together and toa common output terminal Out3 of the two-dimensional array. Outputvoltages are provided between first and second output terminals Out1 andOut2 and the common output terminal Out3.

This two-dimensional array of 2N number of interconnected ConSourceV1/V2/V3 modules can be used as a two-phase AC energy source forstationary energy storage applications for DC or AC single-phase loads.The load can be connected between first and second output terminals Out1and Out2, while the common terminal Out3 can be connected to a neutralof the load, if required.

The first and second output terminals out1 and out2 of the exampletwo-dimensional array based ConSource pack can be connected together viacoupling inductors and connected to the same first terminal of an AC orDC load, when the common output terminal out3 is connected to the secondterminal of the AC or DC load. In this case the output power capabilityof such two-dimensional array based ConSource pack with N rows is twotimes higher than one of the single-dimensional array based ConSourcepack with the same number N of rows.

This two-dimensional array embodiment of system 100 shown in FIG. 16,enables obtaining a two phase system of high voltages with 90 degreephase displacement. For example, such systems can be used in electricalfurnaces. In general, the high voltages of any shape with very low totalharmonic distortion can be obtained between terminals out1, out2 andcommon terminal out3, which can serve as a Neutral, using low and/ormedium voltage rated energy source elements and switching components(MOSFETs, JFETs, IGBTS, etc.) with significantly reduced switching andconduction losses in the ConSource modules.

FIG. 17 shows an example embodiment of a second version of a ConSourcepack including a two-dimensional array 1700 or two one-dimensionalarrays of N and N+1 numbers of interconnected ConSource modules 108-1,108-2 . . . 108-N according to the present disclosure. A principle ofconfiguration and output of DC or AC voltage generation of each of thetwo one-dimensional arrays 1500 with N and N+1 numbers of interconnectedConSource modules, which form this two-dimensional array, is describedabove with regard to FIG. 15. A second port 2 of each of an NthConSource V1/V2/V3 module in Nth or last rows of both of theone-dimensional arrays are connected to first and second ports 1 and 2of an additional or N+1th ConSource V1/V2/V3 module.

This two-dimensional array of 2N+1 number of interconnected ConSourceV1/V2/V3 modules can be used as a single-phase AC energy source forstationary energy storage applications for DC or AC single-phase loads.The load can be connected between first and second output terminals Outland Out2 of a first ConSource V1/V2/V3 module in a first row of each ofthe one-dimensional arrays.

FIG. 18 shows an example embodiment of a first version of a ConSourcepack including a plurality of ConSource V1/V2/V3 modules 108-1, 108-2 .. . 108-N, interconnected in a three-dimensional array 1800, accordingto the present disclosure. First, second and third output terminalsout1, out2 and out3 of the ConSource pack are connected to a first port1 of a first ConSource V1/V2/V3 module of a first row of each of thethree one-dimensional arrays 1500, which form this three-dimensionalarray 1800 based ConSource pack. A principle of configuration and outputof DC or AC voltage generation of each of the three one-dimensionalarrays 1500, which form this three-dimensional array 1800 basedConSource pack, is described above with regard to FIG. 15. A second port2 of an Nth ConSource V1/V2/V3 module in an Nth or last row of each ofthe three one-dimensional arrays are connected together and to a commonoutput terminal out4 of the three-dimensional array. The output voltagesare provided between the first, second and third output terminals out1,out2, out3 and the common output terminal out4.

This three-dimensional array 1800 of 3N interconnected ConSourceV1/V2/V3 modules 108-1, 108-2 . . . 108-N can be used as a three-phaseAC energy source for stationary energy storage or electric vehicleapplications for DC or AC single load, three-phase loads, three phasepower grids or three-phase electric motors 2200, as shown in FIG. 22.The three-phase load can be connected between the first, second andthird output terminals out1, out2, out3, while the common outputterminal out4 can be connected to a neutral of the load, if required.

The first, second and third output terminals out1, out2 and out3 of thethree-dimensional array based ConSource pack can be connected togethervia coupling inductors and connected to the same first terminal of a DCor single-phase AC load, when the common output terminal out4 isconnected to the second terminal of the DC or single phase AC load. Inthis case, the output power capability of such three-dimensional arraybased ConSource pack with N rows is three times higher than the onesingle-dimensional array based ACi-battery pack with the same number Nof rows.

This three-dimensional array 1900 embodiment of system 100 shown in FIG.19 enables obtaining three-phase system of high voltages of any shapewith very low total harmonic distortion between terminals ou1, out2,out3 and common terminal out3 which can serve as a Neutral, using lowand/or medium voltage rated energy source elements and switchingcomponents (MOSFETs, JFETs, IGBTS, etc.) with significantly reducedswitching and conduction losses in the ConSource modules. Such a systemcan be connected to the power distribution grid and can be used as anactive power source or buffer, reactive power compensator and powerfactor corrector, active harmonic filter with very high dynamic responseand significantly reduced size of passive filter between out1, out2,out3 and the phases of power grid. This system can also be connected tothree-phase load providing the energy from energy source elements suchas batteries, supercapacitors, fuel-cells, etc.

FIG. 19 shows an example embodiment of a second version of a ConSourcepack including a plurality of ConSource modules 108 interconnected in athree-dimensional array 1900 according to the present disclosure.

A first port 1 of a ConSource V1/V2/V3 module 108-1 of a first row(“first ConSource V1/V2/V3 module”) of each of the three one-dimensionalarrays 1500 are connected to first, second and third output terminalsout1, out2 and out3 of each of the three one-dimensional arrays, whichform this three-dimensional array based ConSource pack. A principle ofconfiguration and output DC or AC voltage generation of each of thethree one-dimensional arrays with N number of interconnected ConSourceV1/V2/V3 modules, which form this three-dimensional array, is describedabove with regard to FIG. 15. A second port 2 of the first ConSourceV1/V2/V3 modules 108-1 are connected to first ports 1 of ConSourceV1/V2/V3 modules 108-2 in second rows of the three one-dimensionalarrays (“second ConSource V1/V2/V3 modules”). Second ports 2 of thesecond ConSource V1/V2/V3 modules are connected to first ports 1 ofConSource V1/V2/V3 modules in third rows (not shown) of the threeone-dimensional arrays and so on in the same order further down for Mnumber of rows of ConSource V1/V2/V3 modules, wherein M is 2 or greater.

First ports 1 of ConSource V1/V2/V3 modules of M+1th rows are connectedto second ports 2 of ConSource V1/V2/V3 modules of Mth rows (not shown).Second ports 2 of ConSource V1/V2/V3 modules in the M+1th rows areconnected to first ports 1 of ConSource V1/V2/V3 modules in M+2th rows(not shown). Second output ports 2 of ConSource V1/V2/V3 modules in theM+2th rows are connected to first ports 1 of ConSource V1/V2/V3 modulesin M+3th rows (not shown) and so on in the same order further down forM+N number of rows of ConSource V1/V2/V3 modules.

A second port 2 of a ConSource V1/V2/V3 module in a last row or M+Nthrow of a first column 1500 of the three-dimensional array is connectedto the first port 1 of the ConSource V1/V2/V3 module of the M+1 row of asecond column 1500′ of the three-dimensional array. A second port 2 of aConSource V1/V2/V3 module in a last row or M+Nth row of the secondcolumn of the three-dimensional array is connected to the first port 1of the ConSource V1/V2/V3 module of the M+1 row of a third column 1500″of the three-dimensional array. A second port 2 of a ConSource V1/V2/V3module in a last row or M+Nth row of the third column ofthree-dimensional array is connected to the first port 1 of a ConSourceV1/V2/V3 module of a M+1 row of the first column of thethree-dimensional array.

This three-dimensional array of interconnected ConSource V1/V2/V3modules can be used as a three-phase energy source for stationary energystorage or electric vehicle applications for DC or AC single load,three-phase loads, three phase power grids or three-phase electricmotors, as shown in FIG. 23.

In addition to the advantages mentioned with regard to FIG. 18, thisthree-phase (three-dimensional array) configured embodiment of system100 shown in FIG. 19, with a combination of series connected and deltaconnected ConSource modules, enables an effective exchange of energybetween all ConSource modules of the system (inter-phase balancing) andphases of power grid or load. A combination of delta and seriesconnected ConSource modules allow reducing the total number of ConSourcemodules in array to obtain the desired output voltages.

FIG. 20 shows an example embodiment of a third version of a ConSourcepack including a plurality of ConSource modules, interconnected in athree-dimensional array 2000 according to the present disclosure. First,second and third output terminals out1, out2 and out3 of the ConSourcepack are connected to first ports 1 of ConSource V1/V2/V3 modules 108-1of first rows of the three one-dimensional arrays 1500, which form thisthree-dimensional array 2000 based ConSource pack. A principle ofconfiguration and output DC or AC voltage generation of each of thethree one-dimensional arrays with N number of interconnected ConSourceV1/V2/V3 modules 108-1, 108-2 . . . 108-N, which form thisthree-dimensional array, is described above with regard to FIG. 15. Asecond port 2 of a ConSource V1/V2/V3 module of an Nth row of a firstcolumn of the three-dimensional array is connected to a first port 1 ofa first additional ConSource V3 module 108C of an N+1th row. A secondport 2 of a ConSource V1/V2/V3 module of an Nth row of a second columnof the three-dimensional array is connected to a second port 2 of thefirst additional ConSource V3 module 108C of the N+1th row. A secondport 2 of a ConSource V1/V2/V3 module of an Nth row of a third column ofthe three-dimensional array is connected to a first port 1 of a secondadditional ConSource V3 module 108C of an N+1th row. A second port 2 ofthe second additional ConSource V3 module is connected to a fourthoutput terminal Out4 of the ConSource pack. Third and fourth ports 3 and4 of the first and second additional ConSource V3 modules of the N+1throws are interconnected as shown in FIG. 20.

This three-dimensional array of interconnected ConSource V1/V2/V3modules can be used as a three-phase energy source for stationary energystorage or electric vehicle applications for DC or AC single load,three-phase loads, three phase power grids or three-phase electricmotors, as shown in FIG. 24. The three-phase load can be connectedbetween the first, second and third output terminals out1, out2 andout3, while the fourth output terminal out4 can serve as one a chargingterminal.

In addition to the advantages mentioned with regard to FIG. 18, thisthree-phase (three-dimensional array) configured embodiment of system100 shown in FIG. 20, with two additional interconnection ConSource V3modules 108C, enables an effective and fast exchange of energy betweenall ConSource modules of the system (inter-phase balancing) and phasesof power grid or load.

FIG. 21 shows an example embodiment of a fourth version of a ConSourcepack including a plurality of ConSource modules, interconnected in amulti-dimensional array 2100 including K one-dimensional arrays 1500according to the present disclosure, where K, as an example, is 3 orgreater, and illustrated in an example orientation having a plurality ofrows and K columns for presentation and reference purposes only. Each ofthe K one-dimensional arrays 1500 include M+N ConSource V1/V2/V3 modules108-1 . . . 108-(M+N) having first and second ports. Each of the first,Kth and other odd integer one dimensional arrays include an M+N+1thadditional ConSource V3 module 108C having first, second, third andfourth ports.

The first ports 1 of ConSource V1/V2/V3 modules of first rows of each ofthe K number of one-dimensional arrays, respectively, are connected toindividual ones of first and second output terminals out1 and out2 andso on out to a Kth output terminal outK of the K number ofone-dimensional arrays, which form this multi-dimensional array basedConSource pack. The second ports 2 of the ConSource V1/V2/V3 modules inthe first rows are connected to the first ports 1 of ConSource V1/V2/V3modules in second rows (not shown) of each of the K number ofone-dimensional arrays. The second ports 2 of the ConSource V1/V2/V3modules in the second rows are connected to the first ports 1 ofConSource V1/V2/V3 modules in third rows (not shown) of each of the Knumber of one-dimensional arrays, and so on in the same order furtherdown for a M number of rows of ConSource V1/V2/V3 modules, where M is 2or greater.

The second port2 of a ConSource V1/V2/V3 module 108-M of a first arraycolumn of an Mth row is connected to the first port 1 of a ConSourceV1/V2/V3 module 108-1 of a second array column of the first row. Thesecond port2 of a ConSource V1/V2/V3 module 108-M of the second arraycolumn of the Mth row is connected to the first port 1 of a ConSourceV1/V2/V3 module 108-1 of a third array column of the first row, and soon in the same order to a Kth array column, where the second port2 of aConSource V1/V2/V3 module 108-M in the Kth array column of the Mth rowis connected to the first port 1 of the ConSource V1/V2/V3 module 108-1of the first array column of the first row.

The first ports 1 of ConSource V1/V2/V3 modules 108-(M+1) of all of thefirst through Kth array columns of M+1th rows are connected to thesecond ports 2 of the ConSource V1/V2/V3 modules 108-M of the Mth rows.The second ports 2 of ConSource V1/V2/V3 modules 108-(M+1) of all of thefirst through Kth array columns of the M+1th rows are connected to thefirst ports 1 of ConSource V1/V2/V3 modules of all of the first throughKth columns of M+2th rows, and so on in the same order further down foran N number of rows of ConSource V1/V2/V3 modules, where N is 2 orgreater.

The second port 2 of a ConSource V1/V2/V3 module of an M+Nth row of thefirst array column of the multi-dimensional array is connected to thefirst port 1 of a first additional ConSource V3 module of an M+N+1throw. The second port 2 of a ConSource V1/V2/V3 module of the M+Nth rowof the second array column of the multi-dimensional array is connectedto the second port 2 of the first additional ConSource V3 module of theM+N+1th row. The second port 2 of a ConSource V1/V2/V3 module of theM+Nth row of a K−2th array column of the multi-dimensional array isconnected to the first port 1 of a ((K−1)/2)th additional ConSource V3module of the M+N+1th row. The second port 2 of a ConSource V1/V2/V3module of the M+Nth row of a K−1th column of the multi-dimensional arrayis connected to the second port 2 of the ((K−1)/2)th additionalConSource V3 module of the M+N+1th row. The second port 2 of a ConSourceV1/V2/V3 module of the M+Nth row of the Kth column of themulti-dimensional array is connected to a first port 1 of a (K+1)/2 theadditional ConSource V3 module of M+N+1th row. The second port 2 of the(K+1)/2th additional ConSource V3 module is connected to a Kth outputterminal outK+1 of the ConSource pack. The output ports 3 and 4 of all(K+1)/2 additional ConSource V3 modules of M+N+1th rows are connectedtogether as shown in FIG. 21.

This multi-dimensional array of interconnected ConSource V1/V2/V3modules can be used as a multi-phase energy source for stationary energystorage or electric vehicle applications, for DC load, multi-phase ACloads, multi-phase power grids or multi-phase electric motors.

In addition to the advantages mentioned with regard to FIG. 18, thismulti-dimensional array 2100 embodiment of system 100 shown in FIG. 21,with a combination of delta connected and series connected ConSourcemodules and additional interconnection ConSource V3 modules, enables aneffective and fast exchange of energy between all ConSource modules ofthe system (inter-phase balancing) and phases of power grid or load. Acombination of delta and series connected ConSource modules allowreducing the total number of ConSource modules in array to obtain thedesired output voltages.

FIG. 22 and FIG. 23 shows example embodiments of first and secondversions of ConSource packs 1800, 1900, respectively, as presented inFIG. 18 and FIG. 19, respectively, and further connected to athree-phase electrical motors 2200 of any type.

The three-dimensional array 1800 (three-phase motor drive system)embodiment of system 100 shown in FIG. 22, enables obtaining athree-phase system of high voltages of any shape with very low totalharmonic distortion between motor phases A, B and C, using low and/ormedium voltage rated energy source elements and switching components(MOSFETs, JFETs, IGBTS, etc.) with significantly reduced switching andconduction losses. Such a system does not require a usage of bulkypassive filters as in case of 2-level inverter and has a high dynamicresponse.

In addition to the advantages mentioned with regard to FIG. 22, thethree-phase motor drive embodiment 1900 of system 100 (three-dimensionalarray) shown in FIG. 23, with a combination of series connected anddelta connected ConSource modules 108, enables an effective exchange ofenergy between all ConSource modules of the system (inter-phasebalancing) and all phases of electric motor 2200. A combination of deltaand series connected ConSource modules 108 allow reducing the totalnumber of ConSource modules in array to obtain the desired output motorvoltages.

FIG. 24 shows an example embodiment of a third version of a ConSourcepack connected to a three-phase electrical motor 2200 of any type. TheConSource pack is as presented in FIG. 21, where K equals 3, with thethird and fourth output ports 3 and 4 of the two additional ConSource V3modules 108C of the N+1th rows connected together and to a secondAuxiliary Load 2. The two additional ConSource V3 modules of the N+1throws further include fifth and sixth output ports 5 and 6 connectedtogether and to a first Auxiliary Load 1 408. The first Auxiliary Load 1and the second Auxiliary Load 2 410 have different voltages andrepresent, for example, but not limited to, electric vehicle's onboardnetwork system and air-conditioner power supply system, respectively.

In addition to the advantages mentioned with regard to FIG. 21, thisthree-phase motor drive embodiment 2400 of system 100 (three-dimensionalarray) shown in FIG. 24, with a combination of series connected anddelta connected ConSource modules 108 and two additional interconnectionConSource V3 modules 108C, enables an effective and fast exchange ofenergy between all ConSource modules of the system (inter-phasebalancing) and phases of electric motor 2200. A combination of delta andseries connected ConSource modules allow reducing the total number ofConSource modules in array to obtain the desired output motor voltages.The additional output terminals 3, 4, 5, 6 of interconnection ConSourceV3 modules provide low voltages of different levels, which can be usedto provide a power for auxiliary loads, which in turn represent, forexample, the electrical on-board network and HVAC power line of anelectric vehicle. In this case an extra low-voltage battery is notrequired; the energy for above mentioned systems is delivered by entirearray of ConSource modules.

FIG. 25 shows an example embodiment 2500 of a fourth version of aConSource pack connected to a three-phase electrical motor 2200 of anytype. The ConSource pack is as presented in FIG. 20 with the third andfourth output ports 3 and 4 of the two additional ConSource V3 modules108-C of the N+1th rows connected together and to a second AuxiliaryLoad 410. The two additional ConSource V3 modules of the N+1th rowsfurther include fifth and sixth output ports 5 and 6 connected togetherand to a first Auxiliary Load 408. The first Auxiliary Load and secondAuxiliary Load 410 have different voltages and represent, for example,but not limited to, electric vehicle's onboard network system andair-conditioner power supply system, respectively.

In addition to the advantages mentioned with regard to FIG. 22, thisthree-phase motor drive embodiment of system 100 (three-dimensionalarray) shown in FIG. 25, with two additional interconnection ConSourceV3 modules 108C, enables an effective and fast exchange of energybetween all ConSource modules of the system (inter-phase balancing) andphases electric motor. The additional output terminals 3, 4, 5, 6 ofinterconnection ConSource V3 modules 108C provide low voltages ofdifferent levels, which can be used to provide power for auxiliaryloads, which in turn represent, for example, the electrical on-boardnetwork and HVAC power line of an electric vehicle. In this case anextra low-voltage battery is not required; the energy for abovementioned systems is delivered by entire array of ConSource modules.

FIG. 26 shows an example embodiment 2600 of a fifth version of aConSource pack connected to six-phase electrical motor 2650 of any type.The ConSource pack is as presented in FIG. 25 with the first and secondarray columns of the three dimensional array 2500 repeat twice to formsix array columns of a six dimensional array including 3 sets of thefirst and second array columns shown in FIG. 25. The third and fourthports 3 and 4 of the three additional ConSource V3 modules 108C of theN+1 rows are connected together and to the second Auxiliary Load 410 andthe fifth and sixth ports 5 and 6 of the three additional ConSource V3modules 108C of the N+1th rows are connected together and to the firstAuxiliary Load 408. The first Auxiliary Load 408 and the secondAuxiliary Load 410 have different voltages and represent, for example,but not limited to, electric vehicle's onboard network system andair-conditioner power supply system, respectively.

In addition to the advantages mentioned with regard to FIG. 22, thisthree-phase motor drive embodiment of system 100 (three-dimensionalarray) shown in FIG. 26, with three additional interconnection ConSourceV3 modules 108C, enables an effective and fast exchange of energybetween all ConSource modules of the system (inter-phase balancing) andall six phases electric motor. The additional output terminals 3, 4, 5,6 of interconnection ConSource V3 modules provide low voltages ofdifferent levels, which can be used to provide power for auxiliaryloads, which in turn represent, for example, the electrical on-boardnetwork and HVAC power line an electric vehicle. In this case an extralow-voltage battery is not required; the energy for above mentionedsystems is delivered by entire six-dimensional array of ConSourcemodules.

FIG. 27 shows an example embodiment 2700 of a sixth version of aConSource pack including a plurality of ConSource modules,interconnected in three-dimensional array, connected to two three-phaseelectrical motors 2200, 2200′ and auxiliary loads according to thepresent disclosure. The first, second and third output terminals A, Band C of a first Motor 1 2200 are connected to the ConSource pack at thefirst ports 1 of ConSource V1/V2/V3 modules 108-1 of a first row of theConSource pack. The second ports 2 of ConSource V1/V2/V3 modules of theNth row of all three array columns of the ConSource pack are connectedto the first ports 1 of three corresponding ConSource V3 modules 108C ofthe N+1th row, as shown in FIG. 27. The second ports 2 of all three ofthe ConSource V3 modules 108C of the N+1th row are connected to thesecond ports 2 of the ConSource V1/V2/V3 modules of the N+2 row. Thefirst ports 1 of the ConSource V1/V2/V3 modules of the N+2 row areconnected to the second ports 2 of ConSource V1/V2/V3 modules of a N+3throw, and so on in the same order further down to the last row or Mth rowof the ConSource pack, as shown in FIG. 27. The first, second and thirdoutput terminals A′, B′ and C′ of a second Motor 2 2200′ are connectedto the ConSource pack at the first ports 1 of the ConSource V1/V2/V3modules of the Mth row of the ConSource pack.

The third and fourth ports 3 and 4 of the three additional ConSource V3modules 108C of the N+1th row are connected together and to a secondAuxiliary Load 410. The fifth and sixth ports 5 and 6 of the threeadditional ConSource V3 modules 108C of the N+1 row are connectedtogether and to a first Auxiliary Load 408. The first Auxiliary Load 408and the second Auxiliary Load 410 have different voltages and represent,for example, but not limited to, electric vehicle's onboard networksystem and air-conditioner power supply system, respectively.

This three-dimensional array embodiment of system 100 with threeadditional interconnection ConSource V3 modules shown in FIG. 27,provides the independent voltage and frequency regulation (control) fortwo independent motors (dual-motor drive system) and enables aneffective and fast exchange of energy (inter-phase balancing) betweenall ConSource modules of such a dual-motor system and phases of twoelectric motors. The additional output terminals 3, 4, 5, 6 ofinterconnection ConSource V3 modules 108C provide low voltages ofdifferent levels, which can be used to provide power for auxiliaryloads, which in turn represent, for example, the electrical on-boardnetwork and HVAC power line of an electric vehicle. In this case anextra low-voltage battery is not required; the energy for abovementioned systems is delivered by entire array of ConSource modules.

FIG. 28 shows an example embodiment 2800 of a seventh version of aConSource pack including a plurality of ConSource modules 108,interconnected in three-dimensional array, connected to three-phaseopen-winding electrical motor 2850 and auxiliary loads 408, 410according to the present disclosure.

The first ports 1 of ConSource V1/V2/V3 modules 108-1 of the first rowsof all three array columns 2810 are connected together. The second ports2 of the ConSource V1/V2/V3 modules of the first rows of all three arraycolumns are connected to the first ports 1 of ConSource V1/V2/V3 modules(not shown) of the second rows of all three array columns 2810, and soon in the same order further down to the Nth row of each array column.The second ports 2 of ConSource V1/V2/V3 modules 108-N of the Nth rowsof all three array columns are connected to the first, second and thirdinput terminals A, B, C of the open-winding electrical motor 2850, asshown in FIG. 28. The first, second and third terminals A′, B′, C′ ofthe open-winding electrical motor 2850 are connected to the first ports1 of ConSource V1/V2/V3 modules of the N+1th rows of all three arraycolumns. The second ports 2 of the ConSource V1/V2/V3 modules of theN+1th rows of all three array columns are connected to the first ports 1of ConSource V1/V2/V3 modules of the N+2th rows of all three arraycolumns, and so on in the same order further down to Mth row of each ofthe array columns. The second port 2 of ConSource V1/V2/V3 module of theMth row of the first column is connected to the first port 1 of a firstadditional ConSource V3 module 108C of the M+1th row. The second port 2of a ConSource V1/V2/V3 module of the Mth row of the second array columnis connected to the second port 2 of the first additional ConSource V3module 108C of the M+1th row. The second port 2 of a ConSource V1/V2/V3module of the Mth row of the third column is connected to the first port1 of a second additional ConSource V3 module 108C of the M+1th row.

The third and fourth ports 3 and 4 of the two additional ConSource V3modules of the M+1th rows are connected together and to a secondAuxiliary Load 410. The fifth and sixth ports 5 and 6 of the twoadditional ConSource V3 modules of the M+1th rows are connected togetherand to a first Auxiliary Load 408. The first Auxiliary Load and thesecond Auxiliary Load have different voltages and represent, forexample, but not limited to, electric vehicle's onboard network systemand air-conditioner power supply system, respectively.

In addition to the advantages mentioned with regard to FIG. 22, thisthree-phase motor drive embodiment of system 100 (three-dimensionalarray) shown in FIG. 28, with two additional interconnection ConSourceV3 modules, is suitable for open winding motors and enables an effectiveand fast exchange of energy between all ConSource modules of the system(inter-phase balancing) and phases electric motor. The additional outputterminals 3, 4, 5, 6 of interconnection ConSource V3 modules provide lowvoltages of different levels, which can be used to provide power forauxiliary loads, which in turn represent, for example, the electricalon-board network and HVAC power line of an electric vehicle. In thiscase an extra low-voltage battery is not required; the energy for abovementioned systems is delivered by entire array of ConSource modules.

FIG. 29 shows an example embodiment of a eighth version of a ConSourcepack including a plurality of ConSource modules, interconnected inthree-dimensional array 2900, connected to two three-phase open-windingelectrical motors 2850, 2850′ and auxiliary loads 408, 410 according tothe present disclosure.

The first ports 1 of ConSource V1/V2/V3 modules 108-1 of the first rowsof all three array columns are connected together. The second ports 2 ofthe ConSource V1/V2/V3 modules 108-1 of the first rows of all threearray columns are connected to the first ports 1 of ConSource V1/V2/V3modules 108-2 (not shown) of the second rows of all three array columns,and so on in the same order further down to an Nth row. The second ports2 of ConSource V1/V2/V3 modules 108-N of the Nth rows of all three arraycolumns are connected to the first, second and third input terminals A,B, C of a first open-winding electrical motor 2850, as shown in FIG. 29.The first, second and third output terminals A′, B′, C′ of the firstopen-winding electrical motor 2850 are connected to the first ports 1 ofConSource V1/V2/V3 modules 108-(N+1) of the N+1th rows of all threearray columns. The second ports 2 of the ConSource V1/V2/V3 modules108-(N+1) of the N+1th rows of all three array columns are connected tothe first ports 1 of ConSource V1/V2/V3 modules 108-(N+2) of the N+2throws (not shown) of all three array columns, and so on in the same orderfurther down to an Mth row.

The second ports 2 of ConSource V1/V2/V3 modules 108-M of the Mth rowsof all three array columns of the ConSource pack are connected to thefirst ports 1 of three corresponding ConSource V3 modules 108C of theM+1th row, as shown in FIG. 29. The second ports 2 of all threeConSource V3 modules 108C of the M+1th row are connected to the secondports 2 of ConSource V1/V2/V3 modules 108-(M+2) of the M+2th row. Thefirst ports 1 of ConSource V1/V2/V3 modules of the M+2th row areconnected to the second ports 2 of ConSource V1/V2/V3 modules of theM+3th row (not shown), and so on in the same order further down to a Kthrow. The first ports 1 of ConSource V1/V2/V3 modules 108-K of the Kthrows of all three array columns are connected to the first, second andthird input terminals A, B, C of a second open-winding electrical motor2850′, as shown in FIG. 29.

The first, second and third output terminals A′, B′, C′ of the secondopen-winding electrical motor 2850′ are connected to the first ports 1of ConSource V1/V2/V3 modules 108-(K+1) of the K+1th rows of all threearray columns. The first ports 1 of ConSource V1/V2/V3 modules of theK+1th rows of all three array columns are connected to the second ports2 of ConSource V1/V2/V3 modules of the K+2th rows (not shown) of allthree array columns, and so on in the same order further down to an Lthrow. The first ports 1 of ConSource V1/V2/V3 modules the Lth of rows ofall three array columns are connected together.

The third and fourth ports 3 and 4 of the two additional ConSource V3modules of the M+1th rows are connected together and to a secondAuxiliary Load 410. The fifth and sixth ports 5 and 6 of the twoadditional ConSource V3 modules of the M+1 rows are connected togetherand to a first Auxiliary Load 408. The first Auxiliary Load and thesecond Auxiliary Load 410 have different voltages and represent, forexample, but not limited to, electric vehicle's onboard network systemand air-conditioner power supply system, respectively.

This three-dimensional array embodiment of system 100 with threeadditional interconnection ConSource V3 modules shown in FIG. 29,provides the independent voltage and frequency regulation (control) fortwo independent open-winding motors (dual-motor drive system) and allowsan effective and fast exchange of energy (inter-phase balancing) betweenall ConSource modules of such a dual-motor system and phases of twoelectric motors. The additional output terminals 3, 4, 5, 6 ofinterconnection ConSource V3 modules provide low voltages of differentlevels, which can be used to provide power for auxiliary loads, which inturn represent, for example, the electrical on-board network and HVACpower line of an electric vehicle. In this case an extra low-voltagebattery is not required; the energy for above mentioned systems isdelivered by entire array of ConSource modules.

Example Embodiments of Module Control

Turning to FIGS. 30-40B, example systems and methods that facilitatecontrol of system 100 to provide state of charge (SOC) and temperaturebalancing between ConSource modules in different system configurationsare shown. The interconnection architecture of the example embodimentsshown in FIGS. 1 through 29 enables the control of power sharing amongConSource modules. Such control enables maintaining the SOC of theenergy sources of the ConSource modules balanced during cycling and atrest which can help the full capacity of each energy source to beutilized regardless of possible differences in the capacities. Inaddition, it can be used to equalize the temperature of the energysources of ConSource modules. Temperature balancing increases the powercapability of system 100 and provides more uniform aging of the energysources regardless of their location within system 100 and differencesin thermal resistivity.

FIG. 30 depicts an example embodiment of a single-phase AC or DCbalancing controller 3000 that may include a peak detector 3010 (“PeakDetection”), a divider 3020 (“Division”), and an Intra-phase balancingcontroller 3030 (“Intra-phase Balancing Controller”). The peak detectordetects the peak Vpk of the reference voltage Vr. The divider generatesnormalized reference waveform Vrn by dividing the reference voltage Vrby its detected peak Vpk. The Intra-phase balancing controller uses peakvoltage Vpk along with the ConSource status information (e.g., SOCi, Ti,Qi, Vi, etc.) to generate modulation indexes Mi for each module. Theintra-phase balancing controller may be implemented in hardware,software or a combination thereof as a centralized controller, as a partof the MCD, or may be distributed partially or fully among the LCDsdescribed herein.

In the single-phase AC or DC case, the intra-phase balancing controller,as a part of the MCD, receives the reference voltage Vr and collectsstatus information such as state of charge SOCi, temperature Ti,capacity Qi, and voltage Vi from all ConSources of system 100. Thebalancing controller uses these signals to generate Modulation indexesMi and a normalized reference waveform Vrn which is then sent to eachLCD to generate switching signals. The reference waveform Vrn can besent continually, and the modulation index can be sent at regularintervals, such as once for every period of the Vrn. The LCD canmodulate or scale the normalized reference Vrn by the receivedmodulation index. (The modulation index, in some examples, can be anumber between zero and one (inclusive of zero and one).) This modulatedor scaled Vrn can be used as Vref (or −Vref) according to the pulsewidth modulation technique described with respect to FIGS. 14A-14D. Inthis manner, the modulation index can be used to control the PWMswitching signals generated by the LCD, and thus regulate the operationof each ConSource module. For example, a ConSource module beingcontrolled to maintain normal or full operation may receive a modulationindex of one, while a ConSource module that is being controlled to lessthan normal or full operation may receive a modulation index less thanone. A ConSource module that is controlled to cease power output mayreceive a modulation index of zero. Those of ordinary skill in the artwill readily recognize, after reading the present description, thatother values of the modulation index can be used to achieve similarfunctionality.

The intra-phase balancing controller can generates a modulation indexfor each ConSource module according to any number of aspects oroperating characteristics described herein, such as its energy source'sstate of charge, temperature, capacity, and/or voltage in a manner thatfacilitates the following: the sum of the generated ConSource voltagesdoes not exceed the peak voltage Vpk. a different combination ofmodulation indexes may be used but the total generated voltage shouldremain the same, as shown in the phasor diagrams 3100 of FIG. 31; stateof charge (SOC) of the battery modules of ConSources remain balanced orconverge to the balanced condition if they are unbalanced; and thetemperature of the battery modules of ConSources balance when thetemperature of at least one battery module of one ConSource goes above acertain threshold.

Since state of charge and temperature balancing may not be possible atthe same time, a combination of both may be applied with priority givento either one depending on the requirements of the application.

As shown in FIG. 32, a three-phase balancing controller 3200 can includeone inter-phase 3210 and three intra-phase balancing controllers 3220-1,3220-2, 3220-3. The intra-phase balancing controllers' task is tobalance aspects of the ConSource modules within each one-dimensionalarray, in particular and as an example, within one-phase. Theinter-phase balancing controller can balance aspects of the ConSourcemodules among the entire multi-dimensional array, in particular and asan example, among three phases. In a Y-connection of phases, this may beachieved through injecting common mode to the phases (neutral pointshifting) or through common modules or through both. The intra-phasebalancing controllers 3220-1, 3220-2, 3220-3 and inter-phase balancingcontroller 3210 may be implemented in hardware, software or acombination thereof as a centralized controller, as a part of the MCD,or may be distributed partially or fully among the LCDs describedherein.

The reference signal input to this system may be V_(rA), V_(rB), V_(rC)or any combination of two of these signals or any other transformationthat can recreate these signals such as Clarke transform (i.e., V_(rα),V_(rβ)).

In a Y-connected three-phase structure without common modules betweenphases (see, e.g., system 100 as described with respect to FIGS. 18 and22), intra-phase balancing can be achieved by controlling the modulationindexes of the modules within each phase 3300, 3300′, 3300″ as shown inFIG. 33A. By adding certain common modes to the phase references, theneutral point ‘N’ may be shifted 3310 as shown in FIG. 33B. Thisprovides control over the share of each phase to establish the threephase voltages. For example in FIG. 33B, assuming that the system isdischarging and the total energy available in the modules of phase A issmaller than the total energy available in modules of phase C and thatis smaller than the total energy available in modules of phase B, forSOC balancing the neutral point shall be shifted as shown to decreasethe contributions of phase A and C respectively and to increase thecontribution of phase B.

In a Y-connected three-phase structure with common modules betweenphases 3400, 3400′, which are the ConSource V3 modules, (see, e.g.,system 100, FIGS. 20 and 24), intra-phase balancing can be achieved bycontrolling the modulation indexes of the modules within each phase.Inter-phase balancing can be achieved either by: only controlling thecontribution of the common module(s) to each phase as shown in FIG. 34A;neutral point shifting; or both as shown in FIG. 34B.

In four-phase systems 3500, 3500′, as described with respect to FIG. 35Awithout common modules (ConSource V3), and in FIG. 35B with commonmodules (ConSource V3), intra-phase balancing can be achieved bycontrolling the modulation indexes of the modules within each phase.Inter-phase balancing can be achieved by neutral point shifting and/orby controlling the contribution of the common modules to each phasewhere applicable.

In five-phase systems 3600, 3600′, as described with respect to FIG. 36Awithout common modules (ConSource V3), and FIG. 36B with common modules(ConSource V3), intra-phase balancing can be achieved by controlling themodulation indexes of the modules within each phase. Inter-phasebalancing can be achieved by neutral point shifting and/or whereapplicable, by controlling the contribution of the common modules toeach phase.

In six-phase systems 3700, 3700′ as described with respect to FIG. 37Awithout common modules (ConSource V3) and FIG. 37B with common modules(ConSource V3), (modification of system 100, FIG. 26), intra-phasebalancing can be achieved by controlling the modulation indexes of themodules within each phase. Inter-phase balancing can be achieved byneutral point shifting and/or where applicable, by controlling thecontribution of the common modules to each phase.

In system 100 as described with respect to FIG. 27, two systems 3810,3820 of three-phase structures that may run with different voltage andfrequency are considered. The intra-phase balancing can be achievedthrough controlling the modulation indexes of the modules within eachphase. Inter-phase balancing within each system and between the twosystems can be achieved by controlling the voltage contribution of thecommon modules (ConSource V3) to each phase as shown in FIG. 38A.Inter-phase balancing within each system 3810, 3820 may further beimproved by neutral point shifting as shown in FIG. 38B.

In system 100 as described with respect to FIG. 28, two systems ofthree-phase structure that run with similar frequency but may havedifferent voltage are considered.

In FIG. 39A, since complementary phases in the two systems 3900, 3900′work in pairs to generate voltage across each motor winding, modules inphase pairs may be considered for intra-phase balancing. For example, toestablish a certain voltage between A and A′, all the modules in the Aand A′ phases shall contribute respective to their status information.

Inter-phase balancing, or in this case balancing between phase pairs maybe implemented through common modules as shown in FIG. 39A and/orthrough neutral points shift as shown in FIG. 39B.

In system 100 as described with respect to FIG. 29, two systems ofACi-battery packs are connected through common modules and are used todrive two motors. Therefore system 1 and system 2 may operate indifferent voltages and frequencies while in each system the two partsoperate at equal frequency but may have different voltages.

Without the neutral point shift, FIG. 40A intra-phase balancing amongmodules of phase pairs of each system 4010, 4020, 4030 e.g. A₁ and A′₁may be implemented. Inter-phase balancing within and between the twosystems may be achieved through controlling the voltage contribution ofthe common modules to each phase in the two systems.

Neutral point shift as shown in FIG. 40B may be added to improveinter-phase and inter-system 4010, 4020, 4030 balancing.

In many of the embodiments herein, the ConSource module is shown ordescribed as being separate from the LCD. However, in any and allembodiments described herein, the ConSource module can be configuredsuch that the LCD is a component thereof. For example, FIG. 41 is ablock diagram depicting an example embodiment of a converter-sourcemodule 108 (which can also be referred to as a ConSource module V1, V2,or V3). In this embodiment, module 108 has a common housing or physicalencasement 4202 that holds the LCD 114 for module 108, as well as theConverter V1 or V2 206, 308, the Energy Buffer 204 and Energy Source 1202 (and optionally Energy Source 2 304 if present). Thus, in thisembodiment module 108 is provided or manufactured as an integrated orunitary device or sub-system.

FIG. 42 is a block diagram depicting another example embodiment of aconverter-source module 108. In this embodiment, module 108 has ahousing or physical encasement 4203 that holds the LCD for module 108,as well as the Converter V1 or V2 and the Energy Buffer. Energy Source 1202 (and optionally Energy Source 2 304 if present) is provided in aseparate housing 4204. Housings 4203 and 4204 can be physically joinedor connected together prior to installation in system 100, or can beseparate unconnected entities.

In any and all embodiments described herein, the various circuitrycomponents can be integrated on or more substrates to reduce the formfactor. For example, the LCD can be part of a ConSource module asdescribed with respect to FIGS. 41-42. FIG. 43A is a schematic viewdepicting an example embodiment where the LCD 114, converter V1 or V2206, 308, and Energy Buffer 204 are each mounted or secured to a singlecommon substrate 4302, which can be a single printed circuit board(PCB). These components can be electrically coupled with substrate 4302and each other to permit the exchanging of signals or data therebetween.Other passive or active componentry can likewise be mounted or securedto substrate 4302.

FIG. 43B is a schematic view depicting an example embodiment where theconverter V1 or V2 206, 308 and Energy Buffer 204 are each mounted orsecured to a single common substrate 4304, which can be a single printedcircuit board (PCB). These components can be electrically coupled withsubstrate 4304 and each other to permit the exchanging of signals ordata therebetween. The LCD 114 is mounted or secured to a differentsubstrate 4306, which can also be a single PCB. Other passive or activecomponentry can likewise be mounted or secured to substrates 4304 and4306. Communication between the LCD and the components on substrate 4304can occur over one or more buses, wires, or fiber optics.

In the embodiments described herein, intra-phase balancing can beachieved by the one or more intra-phase balancing controllers, andinter-phase balancing can be achieved by one or more inter-phasebalancing controllers. These intra-phase balancing controllers andinter-phase balancing controllers can be implemented in hardware,software, or a combination thereof. These intra-phase balancingcontrollers and inter-phase balancing controllers can be implementedwholly by a device, such as the master control device. These intra-phasebalancing controllers and inter-phase balancing controllers can beimplemented in distributed fashion between multiple devices, such as themaster control device and one or more local control devices.

In FIGS. 1-8F, 11, 13, 15-30, 32, and 1A-1C and 41-43B, variousconstituents of the figures (e.g., elements, components, devices,systems, and/or functional blocks) are depicted as being coupled with orconnected to one or more other constituents (e.g., elements, components,devices, systems, and/or functional blocks). These constituents areoften shown as being coupled or connected without the presence of anintervening entity, such as in a direct coupling or connection. Those ofordinary skill in the art will readily recognize, in light of thepresent description, that these couplings or connections can be direct(without one or more intervening components) or indirect (with one ormore intervening components not shown). Thus, this paragraph serves asantecedent support for all couplings or connections being directcouplings connections or indirect couplings or connections.

A detailed discussion regarding systems (e.g., an ACi-battery pack),devices, and methods that may be used in conjunction with the systems,devices, and methods described herein is provided in InternationalPublication No. WO 2019/183553, filed Mar. 22, 2019, entitled SystemsAnd Methods For Power Management And Control, which is incorporated byreference herein for all purposes as if set forth in full.

The embodiments described herein, when used as a battery pack, e.g., inthe automotive industry, permit the elimination of the conventionalBattery Management System as a sub-system accompanying each batterymodule. The functionality typically performed by the Battery ManagementSystem is subsumed or replaced by the different and in many ways greaterfunctionality of the system embodiments described herein.

A person of ordinary skill in the art would understand that the a“module” as that term is used herein, refers to a device or a sub-systemwithin system 100, and that system 100 does not have to be configured topermit each individual module to be physically removable and replaceablewith respect to the other modules. For example, system 100 may bepackaged in a common housing that does not permit removal andreplacement any one module, without disassembly of the system as awhole. However, any and all embodiments herein can be configured suchthat each module is removable and replaceable with respect to the othermodules in a convenient fashion, such as without disassembly of thesystem.

The term “master control device” is used herein in a broad sense anddoes not require implementation of any specific protocol such as amaster and slave relationship with any other device, such as the localcontrol device.

The term “output” is used herein in a broad sense, and does not precludefunctioning in a bidirectional manner as both an output and an input.Similarly, the term “input” is used herein in a broad sense, and doesnot preclude functioning in a bidirectional manner as both an input andan output.

The terms “terminal” and “port” are used herein in a broad sense, can beeither unidirectional or bidirectional, can be an input or an output,and do not require a specific physical or mechanical structure, such asa female or male configuration.

Various aspects of the present subject matter are set forth below, inreview of, and/or in supplementation to, the embodiments described thusfar, with the emphasis here being on the interrelation andinterchangeability of the following embodiments. In other words, anemphasis is on the fact that each feature of the embodiments can becombined with each and every other feature unless explicitly statedotherwise or logically implausible.

In many embodiments, a module-based energy system includes aconverter-source module. In these embodiments, the converter-sourcemodule includes a first energy source, an energy buffer coupled with thefirst energy source, and a converter coupled with the first energysource and the energy buffer, where the converter includes multipleswitches configured to select an output voltage of the module. In theseembodiments, the module-based energy system further includes a localcontrol device communicatively coupled with the converter-source module,where the local control device is configured to generate multipleswitching signals for the multiple switches.

In many embodiments, a module-based energy system includes aconverter-source module. In these embodiments, the converter-sourcemodule includes a first energy source, an energy buffer coupled with thefirst energy source, and a converter coupled with the first energysource and the energy buffer, where the converter includes multipleswitches configured to select an output voltage of the module. In theseembodiments, the module-based energy system further includes a localcontrol device communicatively coupled with the converter-source module,where the first energy source provides the operating power for the localcontrol device.

In many embodiments, a module-based energy system includes aconverter-source module. In these embodiments, the converter-sourcemodule includes a first energy source, an energy buffer coupled with thefirst energy source, and a converter coupled with the first energysource and the energy buffer, where the converter includes multipleswitches configured to select an output voltage of the module. In theseembodiments, the module-based energy system further includes a localcontrol device communicatively coupled with the converter-source module,where the local control device is configured to detect a fault in theconverter-source module and generate a fault signal. In theseembodiments, the fault signal is indicative of an actual fault or apotential fault. In many of these embodiments, the module-based energysystem further includes a master control device communicatively coupledto the local control device, where the local control device isconfigured to output the fault signal to the master control device.

In many embodiments, a module-based energy system includes aconverter-source module. In these embodiments, the converter-sourcemodule includes a first energy source, an energy buffer coupled with thefirst energy source, and a converter coupled with the first energysource and the energy buffer, where the converter includes multipleswitches configured to select an output voltage of the module. In theseembodiments, the module-based energy system further includes a localcontrol device communicatively coupled with the converter-source module,where the local control device, energy buffer, and converter areimplemented together on a single printed circuit board.

In many embodiments, a module-based energy system includes aconverter-source module. In these embodiments, the converter-sourcemodule includes a first energy source, an energy buffer coupled with thefirst energy source, and a converter coupled with the first energysource and the energy buffer, where the converter includes multipleswitches configured to select an output voltage of the module. In theseembodiments, the module-based energy system further includes a localcontrol device communicatively coupled with the converter-source module,where the local control device, energy buffer, and converter are housedwithin a common housing that does not house the first energy source.

In many embodiments, a module-based energy system includes aconverter-source module. In these embodiments, the converter-sourcemodule includes a first energy source, an energy buffer coupled with thefirst energy source, and a converter coupled with the first energysource and the energy buffer, where the converter includes multipleswitches configured to select an output voltage of the module. In theseembodiments, the module-based energy system further includes a localcontrol device communicatively coupled with the converter-source module,where the local control device, first energy source, energy buffer, andconverter are housed within a common housing that does not house anotherconverter-source module.

In many embodiments, a module-based energy system includes aconverter-source module. In these embodiments, the converter-sourcemodule includes a first energy source, an energy buffer coupled with thefirst energy source, and a converter coupled with the first energysource and the energy buffer, where the converter includes multipleswitches configured to select an output voltage of the module. In theseembodiments, the module-based energy system further includes a localcontrol device communicatively coupled with the converter-source module,where the local control device, energy buffer, and converter are housedwithin a common housing that does not house the first energy source.

In many embodiments, a module-based energy system includes aconverter-source module. In these embodiments, the converter-sourcemodule includes a first energy source, an energy buffer coupled with thefirst energy source, and a converter coupled with the first energysource and the energy buffer, where the converter includes multipleswitches configured to select an output voltage of the module, and wherethe energy buffer and converter are implemented together on a singleprinted circuit board.

In many embodiments, a module-based energy system includes aconverter-source module. In these embodiments, the converter-sourcemodule includes a first energy source including a fuel cell, an energybuffer coupled with the first energy source, and a converter coupledwith the first energy source and the energy buffer, where the converterincludes multiple switches configured to select an output voltage of themodule.

In many embodiments, a module-based energy system includes aconverter-source module. In these embodiments, the converter-sourcemodule includes a first energy source, an energy buffer coupled with thefirst energy source, and a converter coupled with the first energysource and the energy buffer, where the energy buffer includes aZ-source network including two inductors and two capacitors, or a quasiZ-source network including two inductors, two capacitors and a diode. Inthese embodiments, the converter-source module further includes aconverter coupled with the first energy source and the energy buffer,where the converter includes multiple switches configured to select anoutput voltage of the module.

In many embodiments, a module-based energy system includes aconverter-source module. In these embodiments, the converter-sourcemodule includes a first energy source, an energy buffer coupled with thefirst energy source, a second energy source, and a converter including afirst input, a second input, and a third input, where the first andthird inputs are coupled with the first energy source and the energybuffer, where the second and third inputs are coupled with the secondenergy source, where the converter further includes multiple switchesconfigured to select an output voltage of the module, and where both thefirst and second energy sources each include a battery or both the firstand second energy sources each do not include a battery.

In many of these embodiments, the first and second energy sources eachinclude a capacitor or a fuel cell. In many of these embodiments, theconverter includes a first switch, an inductor, and a second switch,where the first switch is coupled between the first input and a firstnode, the inductor is coupled between the second input and the firstnode, and the second switch is coupled between the third input and thefirst node. In many of these embodiments, the multiple switches includea third switch, a fourth switch, a fifth switch, and a sixth switch. Inmany of these embodiments, both the first and second energy sources eachinclude a battery, where the second energy source further includes afirst capacitor in parallel with the battery. In many of theseembodiments, both the first and second energy sources each include abattery, where the second energy source further includes a firstcapacitor in parallel with the battery and a second capacitor inparallel with the battery.

In many embodiments, a module-based energy system includes aconverter-source module. In these embodiments, the converter-sourcemodule includes a first energy source, an energy buffer coupled with thefirst energy source, and a converter coupled with the first energysource and the energy buffer, where the converter includes multipleswitches configured to select an output voltage of the module. In theseembodiments, the converter-source module further includes a first outputport for connection to a primary load or another converter-source moduleand a second output port for connection to an auxiliary load.

In many of these embodiments, the auxiliary load is a first auxiliaryload and the converter-source module includes a third output port forconnection to a second auxiliary load. In many of these embodiments, thefirst output port is coupled with a primary load or anotherconverter-source module, the second output port is coupled with thefirst auxiliary load, and the third output port is coupled with thesecond auxiliary load. In many of these embodiments, the converterincludes a first input, a second input, and a third input, where thefirst and third inputs are coupled with the first energy source, theenergy buffer, and the second output port, and where the second andthird inputs are coupled with the third output port. In many of theseembodiments, the converter includes a first switch, an inductor, and asecond switch, where the first switch is coupled between the first inputand a first node, the inductor is coupled between the second input andthe first node, and the second switch is coupled between the third inputand the first node. In many of these embodiments, the multiple switchesinclude a third switch, a fourth switch, a fifth switch, and a sixthswitch. In many of these embodiments, third switch, fourth switch, fifthswitch, and sixth switch are coupled together as an H-bridge. In many ofthese embodiments, the first output port includes a first output and asecond output, where the third switch is coupled between the first inputand the first output, the fourth switch is coupled between the thirdinput and the first output, the fifth switch is coupled between thefirst input and the second output, and the sixth switch is coupledbetween the third input and the second output.

In many of the aforementioned embodiments, the module-based energysystem further includes multiple converter-source modules coupled withthe converter-source module in an array.

In many of these embodiments, each of the converter-source modules inthe multiple converter-source modules includes a first energy source, anenergy buffer coupled with the first energy source, and a converterincluding multiple switches configured to select an output voltage ofthat converter-source module. In many of these embodiments, the multipleswitches select between a first voltage with a positive polarity, a zeroor reference voltage, and the first voltage with a negative polarity. Inmany of these embodiments, the first voltage is a direct current (DC)voltage. In many of these embodiments, the array is configured to outputan alternating current (AC) signal.

In many of the aforementioned embodiments, the converter includes one ormore sensors configured to output one or more sensed signals indicativeof a temperature of the first energy source, a state of charge of thefirst energy source, a voltage of the first energy source, or a current.

In many of the aforementioned embodiments, the module-based energysystem further includes a local control device communicatively coupledwith the converter-source module.

In many of these embodiments, the module-based energy system furtherincludes multiple converter-source modules and multiple local controldevices, where each local control device in the multiple local controldevices is dedicated for use with one converter-source module of themultiple converter-source modules. In many of these embodiments, theconverter-source module is a first converter-source module, where thesystem includes a second converter-source module, and where the localcontrol device controls both the first and second converter-sourcemodules.

In many of the aforementioned embodiments, the local control deviceincludes processing circuitry and a memory communicatively coupled withthe processing circuitry, where the memory includes instructionsexecutable by the processing circuitry.

In many of the aforementioned embodiments, the local control device isconfigured to generate switching signals for the converter using pulsewidth modulation.

In many of these embodiments, the local control device is configured tomodulate or scale a received reference signal and use the modulatedreference signal for generation of the switching signals. In many ofthese embodiments, the local control device is configured to use areceived modulation index to modulate the received reference signal.

In many of the aforementioned embodiments, the local control device isconfigured to receive one or more signals indicative of one or more ofthe following operating characteristics of the converter-source moduleor a component thereof: temperature, state of charge, capacity, state ofhealth, voltage, or current.

In many of these embodiments, the local control device is configured tocommunicate, to a master control device, information indicative of oneor more of the following operating characteristics of theconverter-source module or a component thereof: temperature, state ofcharge, capacity, state of health, voltage, or current.

In many of the aforementioned embodiments, the local control device ispowered only by the first energy source.

In many of the aforementioned embodiments, the local control device ispowered by an energy source other than the first energy source.

In many of the aforementioned embodiments, the converter-source moduleincludes a second energy source, where the local control device isconfigured to cause the converter-source module to actively filter asecond order harmonic in an output current from the first energy sourcewith current from the second energy source.

In many of these embodiments, the first energy source includes a batteryand the second energy source includes a capacitor. In many of theseembodiments, the capacitor of the second energy source is anultra-capacitor or super-capacitor.

In many of the aforementioned embodiments, the converter-source moduleincludes a second energy source, where the local control device isconfigured to control the converter to manage power transfer: from thefirst energy source to a cumulative load of converter-source modules,from the second energy source to the cumulative load of converter-sourcemodules, and between the first energy source and second energy source.

In many of these embodiments, power transfer between the first energysource and second energy source includes power transfer from the firstenergy source to the second energy source and power transfer from thesecond energy source to the first energy source. In many of theseembodiments, the local control device is configured to control theconverter to manage power transfer based, at least in part, on a powerconsumption of a first auxiliary load and a power consumption of asecond auxiliary load. In many of these embodiments, the local controldevice includes a processor and memory, where the memory includesinstructions that, when executed by the processing circuitry, cause theprocessing circuitry to manage power transfer: from the first energysource to a cumulative load of converter-source modules, from the secondenergy source to the cumulative load of converter-source modules, andbetween the first energy source and second energy source. In many ofthese embodiments, the local control device is configured to managepower transfer by generation of switching signals for the converter.

In many of the aforementioned embodiments, the module-based energysystem further includes a master control device configured to manage oneor more operating parameters of the converter-source module relative toone or more operating parameters of other converter-source moduleswithin the system.

In many of the aforementioned embodiments, the module-based energysystem further includes a master control device communicatively coupledwith the local control device.

In many of these embodiments, the master control device iscommunicatively coupled with the local control device over a serial datacable. In many of these embodiments, the master control device includesprocessing circuitry and a memory communicatively coupled with theprocessing circuitry, where the memory includes instructions executableby the processing circuitry. In many of these embodiments, themodule-based energy system further includes multiple local controldevices coupled with multiple converter-source modules, where the mastercontrol device is communicatively coupled with each of the local controldevices of the multiple local control devices. In many of theseembodiments, the master control device is configured to read dataindicative of one or more operating characteristics of the multipleconverter-source modules, and to determine a contribution for at leastone converter-source module of the multiple converter-source modules. Inmany of these embodiments, the master control device is configured todetermine a contribution for each of the multiple converter-sourcemodules. In many of these embodiments, the master control device isconfigured to output a modulation or scaling index for each of themultiple converter-source modules, where the modulation or scaling indexis indicative of power flow contribution. In many of these embodiments,the master control device is configured to output a reference signal toeach of the local control devices, where each of the local controldevices is configured to modulate or scale the reference signal with areceived modulation or scaling index, and generate switching signalsbased on the modulated or scaled reference signal.

In many of the aforementioned embodiments, the module-based energysystem is configured for operation in a mobile entity.

In many of these embodiments, the mobile entity is one of: a car, a bus,a truck, a motorcycle, a scooter, an industrial vehicle, a miningvehicle, a flying vehicle, a maritime vessel, a locomotive, a train orrail-based vehicle, or a military vehicle.

In many of the aforementioned embodiments, the module-based energysystem is configured for operation as a stationary energy system.

In many of these embodiments, the stationary energy system is one of: aresidential storage system, an industrial storage system, a commercialstorage system, a data center storage system, a grid, a micro-grid, or acharging station.

In many of the aforementioned embodiments, the module-based energysystem is configured as a battery pack for an electric vehicle.

In many embodiments, a module-based energy system includes multipleconverter-source modules, each including a first energy source, anenergy buffer, and a converter electrically coupled together, where themultiple converter-source modules are electrically coupled together inan array. In these embodiments, the module-based energy system furtherincludes control circuitry communicatively coupled with the multipleconverter-source modules, where the control circuitry is configured tomonitor at least one operating characteristic of each of the multipleconverter-source modules and, based on the monitored at least oneoperating characteristic, independently control each converter-sourcemodule within the multiple converter-source modules for performanceoptimization of the array.

In many of these embodiments, the at least one operating characteristicis selected from: state of charge, temperature, state of health,capacity, fault presence, voltage, or current. In many of theseembodiments temperature is at least one of: a temperature of the firstenergy source or a component thereof, a temperature of the energy bufferor a component thereof, a temperature of the converter or a componentthereof. In many of these embodiments, capacity is at least one of:capacity of the first energy source or capacity of one or morecomponents of the first energy source. In many of these embodiments,fault presence is at least one of: an indication of the presence of ameasured fault, an indication of the presence of a potential fault; anindication of the presence of an alarm condition, or an indication ofthe presence of a warning condition. In many of these embodiments,voltage is at least one of: a voltage of the first energy source or acomponent thereof, a voltage of the energy buffer or a componentthereof, a voltage of the converter or a component thereof. In many ofthese embodiments, current is at least once of: a current of the firstenergy source or a component thereof, a current of the energy buffer ora component thereof, a current of the converter or a component thereof.In many of these embodiments, each converter-source module includes atleast one sensor to sense the at least one operating characteristic. Inmany of these embodiments, the control circuitry is configured tomonitor all of the following operating characteristics: state of charge,temperature, state of health, capacity, fault presence, voltage, andcurrent. In many of these embodiments, the control circuitry isconfigured to independently control discharging or charging of eachconverter-source module by generation of multiple switching signals andoutput of the multiple switching signals to the converter of eachconverter-source module. In many of these embodiments, the controlcircuitry is configured to generate the multiple switching signals withpulse width modulation or hysteresis.

In many of these embodiments, at least one converter-source module ofthe multiple converter-source modules is a converter-source module asdescribed in many of the aforementioned embodiments.

In many of these embodiments, every converter-source module of themultiple converter-source modules is a converter-source module asdescribed in many of the aforementioned embodiments.

In many of these embodiments, the control circuitry is configured toindependently control discharging or charging of each converter-sourcemodule within the multiple converter-source modules for performanceoptimization of the array. In many of these embodiments, the controlcircuitry is configured to independently control discharging or chargingof each converter-source module based on a power requirement of a loadcoupled with the array. In many of these embodiments, the load is amotor, a commercial structure, a residential structure, an industrialstructure, or an energy grid. In many of these embodiments, the controlcircuitry includes multiple local control devices and a master controldevice communicatively coupled with the multiple local control devices.

In many embodiments, a module-based energy system includes an array of Nconverter-source modules, where N is 2 or greater, where each of the Nconverter-source modules is connected in series, where each of the Nconverter-source modules is configured according to any of theaforementioned embodiments, and where the array includes a first outputterminal of a first converter-source module and a second output terminalof an Nth converter-source module.

In many of these embodiments, the module-based energy system furtherincludes multiple local control devices, each communicatively coupledwith one or more of the N converter-source modules. In many of theseembodiments, the module-based energy system further includes a mastercontroller communicatively coupled with the multiple local controldevices. In many of these embodiments, the module-based energy systemfurther includes a load connected between the first and second outputterminals. In many of these systems, the load is one of a DC load or asingle-phase AC load.

In many embodiments, a module-based energy system includes M arrays ofconverter-source modules, where M is 2 or greater, where each of the Marrays includes N converter-source modules, where N is 2 or greater,where each of the N converter-source modules is connected in series ineach of the M arrays, where each of the N converter-source modules isconfigured according to any of aforementioned embodiments, where each ofthe M arrays includes an individual output terminal of a firstconverter-source module, and where an Nth converter-source module ofeach of the M arrays is connected to a common output terminal.

In many of these embodiments, the module-based energy system furtherincludes multiple local control devices, each communicatively coupledwith one or more of the N converter-source modules of each of the Marrays. In many of these embodiments, the module-based energy systemfurther includes a master controller communicatively coupled with themultiple local control devices. In many of these embodiments, the Marrays includes first and second arrays. In many of these embodiments,the module-based energy system further includes a load connected betweenthe individual output terminals of the first and second arrays. In manyof these embodiments, the common output terminal is coupled to a neutralof the load. In many of these embodiments, the module-based energysystem further includes a load connected between the common outputterminal and a joint coupling of the individual output terminals of thefirst and second arrays. In many of these embodiments, the load is oneof a DC load or a single-phase AC load. In many of these embodiments,the M arrays includes first, second and third arrays. In many of theseembodiments, the module-based energy system further includes athree-phase load connected between the individual output terminals ofthe first, second and third arrays. In many of these embodiments, thecommon output terminal is coupled to a neutral of the load. In many ofthese embodiments, the module-based energy system further includes a DCor single phase AC load connected between the common output terminal anda joint coupling of the individual output terminals of the first, secondand third arrays.

In many embodiments, a module-based energy system includes first andsecond arrays of converter-source modules, where the first arrayincludes N converter-source modules and the second array includes N−1converter-source modules, where N is 2 or greater, where each of the Nconverter-source modules is connected in series in the first array andeach of the N−1 converter-source modules is connected in series in thesecond array, where each of the N converter-source modules and N−1converter-source modules includes an energy source, an energy buffer anda converter, where each of the first and second arrays includes anindividual output terminal of a first converter-source module, and wherean Nth converter-source module of each of the first array and an N−1thconverter-source module of the second array are connected to a commonoutput terminal.

In many of these embodiments, the module-based energy system furtherincludes multiple local control devices, each communicatively coupledwith one or more of the N converter-source modules and N−1converter-source modules. In many of these embodiments, the module-basedenergy system further includes a master controller communicativelycoupled with the multiple local control devices. In many of theseembodiments, the module-based energy system further includes a loadconnected between the individual output terminals of the first andsecond arrays. In many of these embodiments, the common output terminalis coupled to a neutral of the load. In many of these embodiments, themodule-based energy system further includes a load connected between thecommon output terminal and a joint coupling of the individual outputterminals of the first and second arrays. In many of these embodiments,the load is one of a DC load or a single-phase AC load. In many of theseembodiments, the load is one of a DC load or a single-phase AC load.

In many embodiments, a module-based energy system includes first, secondand third arrays of converter-source modules, where each of the first,second and third arrays includes N+M converter-source modules, where Nis 2 or greater and M is 2 or greater, where each of the N+Mconverter-source modules includes an energy source, an energy buffer anda converter, where each of the N+M converter-source modules includesfirst and second ports, where each of the first, second and third arraysincludes an individual output terminal coupled to a first port of afirst converter-source module, where the first converter-source modulethrough an Nth converter-source module of each of the first, second andthird arrays are connected in series, where the Nth converter-sourcemodule through an N+Mth converter-source module of each of the first,second and third arrays are connected in series, where the second portof the N+Mth converter-source module of the first array is connected tothe first port of the Nth converter-source module of the second array,where the second port of the N+Mth converter-source module of the secondarray is connected to the first port of the Nth converter-source moduleof the third array, and where the second port of the N+Mthconverter-source module of the third array is connected to the firstport of the Nth converter-source module of the first array.

In many of these embodiments, the series connection of the firstconverter-source module through an Nth converter-source module of eachof the first, second and third arrays includes the first port of asecond converter-source module through an Nth converter-source module ofeach of the first, second and third arrays being connected to the secondport of a preceding converter-source module in a series ofconverter-source modules including the first converter-source modulethrough an N−1th converter-source module. In many of these embodiments,the series connection of the Nth converter-source module through anN+Mth converter-source module of each of the first, second and thirdarrays includes the first port of an Nth+1 converter-source modulethrough the N+Mth converter-source module of each of the first, secondand third arrays being connected to the second port of a precedingconverter-source module in a series of converter-source modulesincluding the Nth converter-source module through an N+(M−1)thconverter-source module. In many of these embodiments, the module-basedenergy system further includes multiple local control devices, eachcommunicatively coupled with one or more of the N+M converter-sourcemodules. In many of these embodiments, the module-based energy systemfurther includes a master controller communicatively coupled with themultiple local control devices. In many of these embodiments, themodule-based energy system further includes a load connected between theindividual output terminals of the first, second and third arrays. Inmany of these embodiments, the load is one of a DC or single-phase ACload, or three-phase AC loads.

In many embodiments, a module-based energy system includes first, secondand third arrays of converter-source modules, where each of the firstand third arrays includes N+1 converter-source modules and the secondarray includes N converter-source modules, where N is 2 or greater,where each of a first converter-source module through an Nthconverter-source module includes an energy source, an energy buffer anda converter, where an N+1th converter-source module of each of the firstand third arrays includes an energy source, an energy buffer, aconverter and is configured for connection to one or more auxiliaryloads, where each of the first converter-source module through the Nthconverter-source module includes first and second ports, where the N+1thconverter-source module of each of the first and third arrays includesfirst, second, third and fourth ports, where first, second and thirdoutput terminals, respectively, are coupled to the first port of thefirst converter-source module of the first, second and third arrays,respectively, where the first converter-source module through the Nthconverter-source module of each of the first, second and third arraysare connected in series, where the second port of Nth converter-sourcemodule of each of the first and third arrays, respectively, areconnected to the first port of N+1th converter-source module of each ofthe first and third arrays, respectively, where the second port of theN+1th converter-source module of the first array is connected to thesecond port of the Nth converter-source module of the second array,where the second port of the N+1th converter-source module of the thirdarray is connected to a fourth output terminal, and where the third andfourth ports, respectively, of the N+1th converter-source module of thefirst array are connected to the third and fourth ports, respectively,of the N+1th converter-source module of the third array.

In many of these embodiments, the second port of a secondconverter-source module of the third array is connected to the firstport of the first converter-source module of the first array. In many ofthese embodiments, the N+1th converter-source module of each of thefirst and third arrays further include fifth and sixth ports, and wherethe one or more auxiliary loads of the N+1th converter-source module ofthe first and third arrays include a first auxiliary load connected tothe fifth and sixth ports of the N+1th converter-source module of eachof the first and third arrays and a second auxiliary load connected tothe third and fourth ports of the N+1th converter-source module of eachof the first and third arrays. In many of these embodiments, themodule-based energy system further includes multiple local controldevices, each communicatively coupled with one or more of the N+1converter-source modules of the first and third arrays and the Nconverter-source modules of the second array. In many of theseembodiments, the module-based energy system further includes a mastercontroller communicatively coupled with the multiple local controldevices. In many of these embodiments, the module-based energy systemfurther includes multiple local control devices, each communicativelycoupled with one or more of the N+1 converter-source modules of thefirst and third and the N converter-source modules of the second array.In many of these embodiments, the module-based energy system furtherincludes a master controller communicatively coupled with the multiplelocal control devices. In many of these embodiments, the module-basedenergy system further includes a load connected between the first,second and third output terminals of the first, second and third arrays.In many of these embodiments, the load is one of a DC or single-phase ACload, or three-phase AC loads. In many of these embodiments, themodule-based energy system further includes a load connected between thefirst, second and third output terminals of the first, second and thirdarrays. In many of these embodiments, the module-based energy systemfurther includes a load connected between the first, second and thirdoutput terminals of the first, second and third arrays. In many of theseembodiments, the load is one of a DC or single-phase AC load, orthree-phase AC loads.

In many embodiments, a module-based energy system includes first,second, third, fourth, fifth and sixth arrays of converter-sourcemodules, where each of the first, third and fifth arrays includes N+1converter-source modules and each of the second, fourth and sixth arraysincludes N converter-source modules, where N is 2 or greater, where eachof the N converter-source modules and N+1 converter-source modulesincludes an energy source, an energy buffer and a converter, where eachof the first converter-source module through the Nth converter-sourcemodule includes first and second ports, where the N+1th converter-sourcemodule of each of the first, third and fifth arrays include first,second, third, fourth, fifth and sixth ports, and where a firstauxiliary load is connected to the fifth and sixth ports of the N+1thconverter-source module of each of the first, third and fifth arrays anda second auxiliary load connected to the third and fourth ports of theN+1th converter-source module of each of the first, third and fiftharrays, where first, second, third, fourth, fifth and sixth outputterminals, respectively, are coupled to the first port of the firstconverter-source module of the first, second, third, fourth, fifth andsixth arrays, respectively, where the first converter-source modulethrough the Nth converter-source module of each of the first, second,third, fourth, fifth and sixth arrays are connected in series, where thesecond port of Nth converter-source module of each of the first, thirdand fifth arrays, respectively, are connected to the first port of N+1thconverter-source module of each of the first, third and fifth arrays,respectively, where the second port of the N+1th converter-source moduleof the first array is connected to the second port of the Nthconverter-source module of the second array, where the second port ofthe N+1th converter-source module of the third array is connected to thesecond port of the Nth converter-source module of the fourth array, andwhere the second port of the N+1th converter-source module of the fiftharray is connected to the second port of the Nth converter-source moduleof the sixth array.

In many of these embodiments, the module-based energy system furtherincludes multiple local control devices, each communicatively coupledwith one or more of the N+1 converter-source modules of the first, thirdand fifth arrays and one or more of the N converter-source modules ofthe second, fourth and sixth arrays. In many of these embodiments, themodule-based energy system further includes a master controllercommunicatively coupled with the multiple local control devices. In manyof these embodiments, the energy system further includes a loadconnected between the first, second, third, fourth, fifth and sixthoutput terminals of the first, second, third, fourth, fifth and sixtharrays. In many of these embodiments, the load is a six-phase AC load.

In many embodiments, a module-based energy system includes Kone-dimensional arrays of interconnected converter-source modules, whereK is 3 or greater and is an odd integer, each of the first and Ktharrays and every odd integer array there between includes N+M+1converter-source modules and each of every even integer array between asecond array and an K−1th array includes N+M converter-source modules,and where N and M are 2 or greater, where each of a firstconverter-source module through an N+Mth converter-source moduleincludes an energy source, an energy buffer and a converter, where anN+M+1th converter-source module of each of the first, Kth and other oddinteger arrays includes an energy source, an energy buffer, a converterand is configured for connection to one or more auxiliary loads, whereeach of the first converter-source module through the N+Mthconverter-source module of each of the K arrays includes first andsecond ports, where the N+M+1th converter-source module of each of thefirst, Kth and other odd integer arrays includes first, second, thirdand fourth ports, where K individual output terminals are coupled to thefirst port of the first converter-source module of each of the K arrays,respectively, where the first converter-source module through the N+Mthconverter-source module of each of the K arrays are connected in series,where the second port of N+Mth converter-source module of each of thefirst, Kth and other odd integer arrays, respectively, are connected tothe first port of N+M+1th converter-source module of each of the first,Kth and other odd integer arrays, respectively, where the second port ofthe N+Mth converter-source module of the second, K−1th and other eveninteger arrays there between is connected to the second port of theN+M+1th converter-source module of a preceding array of the K arrays,where the second port of the N+M+1th converter-source module of the Ktharray is connected to a K+1th output terminal, and where the third andfourth ports, respectively, of the N+M+1th converter-source module ofthe first, Mth and other odd integer arrays are connected to oneanother.

In many of these embodiments, the second port of a Nth converter-sourcemodule of the Kth array is connected to the first port of the firstconverter-source module of the first array. In many of theseembodiments, the first port of the first converter-source module in thesecond through Kth array is connected to the second port of the Nthconverter-source module of the preceding array. In many of theseembodiments, the module-based energy system further includes multiplelocal control devices, each communicatively coupled with one or more ofthe N+M+1 converter-source modules of the first, Kth and other oddinteger arrays and each of the N+M converter-source modules of thesecond, M−1th and other even integer arrays. In many of theseembodiments, the module-based energy system further includes a mastercontroller communicatively with the multiple local control devices. Inmany of these embodiments, the module-based energy system furtherincludes a multi-phase load connected between the first through Kthoutput terminals of the K arrays. In many of these embodiments, themodule-based energy system further includes a multi-phase load connectedbetween the first through Kth output terminals of the K arrays. In manyof these embodiments, the module-based energy system further includes aload connected between the first, second and third output terminals ofthe M arrays. In many of these embodiments, the module-based energysystem further includes a load connected between the first, second andthird output terminals of the M arrays. In many of these embodiments,the load is one of a DC or single-phase AC load, or three-phase ACloads.

In many embodiments, a module-based energy system includes first,second, third, fourth, fifth and sixth arrays of N converter-sourcemodules, where N is 2 or greater, where each of the N converter-sourcemodules includes an energy source, an energy buffer and a converter, andfirst and second ports, where first, second, third, fourth, fifth andsixth output terminals, respectively, are coupled to the first port ofthe first converter-source module of the first, second, third, fourth,fifth and sixth arrays, respectively, where a first three-phase AC loadis connected between the first, second and third output terminals of thefirst, second and third arrays, where a second three-phase AC load isconnected between the fourth, fifth and sixth output terminals of thefourth, fifth and sixth arrays, where the N converter-source modules ofeach of the first, second, third, fourth, fifth and sixth arrays areconnected in series, where the second port of the Nth converter-sourcemodule of the first array is connected to the second port of the Nthconverter-source module of the fourth array, where the second port ofthe Nth converter-source module of the second array is connected to thesecond port of the Nth converter-source module of the fifth array, wherethe second port of the Nth converter-source module of the third array isconnected to the second port of the Nth converter-source module of thesixth array, where the Nth converter-source module of each of the first,second and third arrays further includes third, fourth, fifth and sixthports, and where a first auxiliary load is connected to the fifth andsixth ports of the Nth converter-source module of each of the first,second and third arrays and a second auxiliary load connected to thethird and fourth ports of the Nth converter-source module of each of thefirst, third and third arrays.

In many of these embodiments, the module-based energy system furtherincludes multiple local control devices, each communicatively coupledwith one or more of the N converter-source modules of the first, second,third, fourth, fifth and sixth arrays. In many of these embodiments, themodule-based energy system further includes a master controllercommunicatively coupled with the multiple local control devices.

In many embodiments, a module-based energy system includes first,second, third and fifth arrays of N converter-source modules and fourthand sixth arrays of N+1 converter-source modules, where N is 2 orgreater, where each of the N converter-source modules and N+1converter-source modules includes an energy source, an energy buffer anda converter, and first and second ports, where first, second, third,fourth, fifth and sixth output terminals, respectively, are coupled tothe first port of the first converter-source module of the first,second, third, fourth, fifth and sixth arrays, respectively, where asix-phase AC load is connected between the first, second, third, fourth,fifth and sixth output terminals of the first, second, third, fourth,fifth and sixth arrays, where the N converter-source modules of each ofthe first, second, third and fifth arrays and the N+1 converter-sourcemodules of each of the fourth and sixth arrays are connected in series,where the second port of the N+1th converter-source module of the fourtharray is connected to the second port of the Nth converter-source moduleof the fifth array, where the second port of the N+1th converter-sourcemodule of the sixth array is connected to a fourth output terminal,where the N+1th converter-source module of each of the fourth and sixtharrays further includes third, fourth, fifth and sixth ports, and wherea first auxiliary load is connected to the fifth and sixth ports of theNth converter-source module of each of the first, second and thirdarrays and a second auxiliary load connected to the third and fourthports of the Nth converter-source module of each of the first, third andthird arrays.

In many of these embodiments, the module-based energy system furtherincludes multiple local control devices, each communicatively coupledwith one or more of the N converter-source modules of the first, secondand third arrays and N+1 converter-source modules of the fourth andsixth arrays. In many of these embodiments, the module-based energysystem further includes a master controller communicatively coupled withthe multiple local control devices.

In many embodiments, a module-based energy system includes first,second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth,eleventh and twelfth arrays of N converter-source modules, where N is 2or greater, where each of the N converter-source modules includes anenergy source, an energy buffer and a converter, and first and secondports, where first, second, third, fourth, fifth, sixth, seventh,eighth, ninth, tenth, eleventh and twelfth output terminals,respectively, are coupled to the first port of the firstconverter-source module of the first, second, third, fourth, fifth,sixth, seventh, eighth, ninth, tenth, eleventh and twelfth arrays,respectively, where a first six-phase AC load is connected between thefirst, second, third, seventh, eighth and ninth output terminals of thefirst, second, third, seventh, eighth and ninth arrays, where a secondthree-phase AC load is connected between the fourth, fifth, sixth,tenth, eleventh and twelfth output terminals of the fourth, fifth,sixth, tenth, eleventh and twelfth arrays, where the N converter-sourcemodules of each of the first, second, third, fourth, fifth, sixth,seventh, eighth, ninth, tenth, eleventh and twelfth arrays are connectedin series, where the second port of the Nth converter-source module ofthe first array is connected to the second port of the Nthconverter-source module of the fourth array, where the second port ofthe Nth converter-source module of the second array is connected to thesecond port of the Nth converter-source module of the fifth array, wherethe second port of the Nth converter-source module of the third array isconnected to the second port of the Nth converter-source module of thesixth array, where the Nth converter-source module of each of the first,second and third arrays further includes third, fourth, fifth and sixthports, and where a first auxiliary load is connected to the fifth andsixth ports of the Nth converter-source module of each of the first,second and third arrays and a second auxiliary load connected to thethird and fourth ports of the Nth converter-source module of each of thefirst, third and third arrays.

In many of these embodiments, the module-based energy system furtherincludes multiple local control devices, each communicatively coupledwith one or more of the N converter-source modules of the first, second,third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh andtwelfth arrays. In many of these embodiments, the module-based energysystem further includes a master controller communicatively coupled withthe multiple local control devices.

In many embodiments, a module-based energy system includes multipleinterconnected converter-source modules and control circuitry, where thecontrol circuitry is configured to adjust a contribution of one or moreof the converter-source modules based on status information associatedwith one or more of the converter-source modules.

In many of these embodiments, the converter-source module includes aconverter-source module according to many of the aforementionedembodiments.

In many of these embodiments, the converter-source module includes anenergy source including at least one energy storage element, an energybuffer, and a converter. In many of these embodiments, the statusinformation includes one or more of state of charge, state of health,temperature, capacity, current, or voltage of the converter-sourcemodule or a component thereof. In many of these embodiments, the mastercontrol device is configured to balance state of charge (SOC) of themultiple interconnected converter-source modules. In many of theseembodiments, the control circuitry includes processing circuitry and atleast one memory having instructions stored thereon that, when executedby the processing circuitry, cause the processing circuitry to causeadjustment of the contribution of one or more converter-source modulesbased on status information associated with one or more of theconverter-source modules. In many of these embodiments, the processingcircuitry and at least one memory are components of a master controldevice, a local control device, or distributed between a master controldevice and one or more local control devices.

In many of these embodiments, the control circuitry is configured tocause the contribution of a first converter-source module to be loweredwith respect to one or more other converter-source modules based onstatus information of the first converter-source module and the one ormore other converter-source modules. In many of these embodiments, thestatus information of the first converter-source module indicates atleast one of the following as compared to status information of the oneor more other converter-source modules: a relatively lower state ofcharge, a relatively lower state of health, a relatively lower capacity,a relatively lower voltage, a relatively lower current, a relativelyhigher temperature, or a fault.

In many of these embodiments, the control circuitry is configured tocause the contribution of a first converter-source module to be raisedwith respect to one or more other converter-source modules based onstatus information of the first converter-source module and the one ormore other converter-source modules. In many of these embodiments, thestatus information of the first converter-source module indicates atleast one of the following as compared to status information of the oneor more other converter-source modules: a relatively higher state ofcharge, a relatively higher state of health, a relatively highercapacity, a relatively higher voltage, a relatively higher current, arelatively lower temperature, or absence of a fault.

In many of these embodiments, the contribution is an output power overtime of the first converter-source module. In many of these embodiments,the control circuitry includes a master control device and multiplelocal control devices. In many of these embodiments, the master controldevice is configured to generate a multiple modulation indexes for themultiple converter-source modules, with one modulation indexindependently generated for each converter-source module of the multipleconverter-source modules.

In many of these embodiments, the master control device includes anintra-phase balancing controller. In many of these embodiments, theintra-phase balancing controller is configured to generate a modulationindex for each converter-source module. In many of these embodiments, amodulation index for a converter-source module is determined based onone or more of a peak voltage Vpk of a reference voltage Vr of themodule-based energy system, state of charge of the converter-sourcemodule, temperature of the converter-source module, capacity of theconverter-source module, current of the converter-source module, orvoltage of the converter-source module. In many of these embodiments,the master control device further includes a peak detector for detectinga peak voltage Vpk of a reference voltage Vr of the module-based energysystem. In many of these embodiments, the master control device isconfigured to generate a normalized reference waveform Vrn from areference voltage Vr. In many of these embodiments, the master controldevice is configured to generate the normalized reference waveform Vrnfrom the reference voltage Vr by division of the reference voltage Vr byits peak voltage Vpk. In many of these embodiments, the master controldevice is configured to output a normalized reference waveform Vrn toeach of the multiple local control devices. In many of theseembodiments, each local control device of the multiple local controldevices is configured to modulate the received normalized referencewaveform Vrn by the received modulation index. In many of theseembodiments, each local control device of the multiple local controldevices is configured to generate switching signals for aconverter-source module based on the modulated reference waveform. Inmany of these embodiments, each local control device of the multiplelocal control devices is configured to generate switching signals for aconverter-source module based on a pulse width modulation techniqueimplemented with the modulated reference waveform.

In many of these embodiments, the multiple modulation indexes isgenerated to ensure a sum of generated voltages from the multipleconverter-source modules does not exceed a peak voltage Vpk. In many ofthese embodiments, the multiple modulation indexes Mi are generated tocause states of charge (SOC) of energy sources of the multipleconverter-source modules to converge towards a balanced condition. Inmany of these embodiments, the multiple modulation indexes Mi aregenerated to cause states of health (SOH) of the multipleconverter-source modules to converge towards a balanced condition. Inmany of these embodiments, the multiple modulation indexes Mi aregenerated to cause capacities of the multiple converter-source modulesto converge towards a balanced condition. In many of these embodiments,the multiple modulation indexes Mi are generated to cause voltages ofthe multiple converter-source modules to converge towards a balancedcondition. In many of these embodiments, the multiple modulation indexesMi are generated to cause currents of the multiple converter-sourcemodules to converge towards a balanced condition. In many of theseembodiments, the multiple modulation indexes Mi are generated to causetemperatures of the multiple converter-source modules to convergetowards a balanced condition. In many of these embodiments, the multiplemodulation indexes Mi are generated to reduce the contribution of one ormore converter-source modules having a fault condition as compared toone or more other converter source modules not having a fault condition.

In many of these embodiments, the control circuitry includes one or bothof an inter-phase balancing controller or an intra-phase balancingcontroller. In many of these embodiments, the multiple converter-sourcemodules is arranged in a multi-dimensional array. In many of theseembodiments, the intra-phase balancing controller is configured toadjust a contribution of the multiple converter-source modules within aone-dimensional array of the multi-dimensional array. In many of theseembodiments, the inter-phase balancing controller is configured tocontrol one or more of neutral point shifting or contribution ofconverter-source modules that are common to each phase.

In many of the aforementioned embodiments, the module-based energysystem is one of single phase or multi-phase. In many of theseembodiments, the module-based energy system is a multi-phasemodule-based energy system outputting signals in three-phases,four-phases, five-phases, or six-phases.

In many of the aforementioned embodiments, the multiple converter-sourcemodules are arranged in a multi-dimensional array.

In many of the aforementioned embodiments, the multiple converter-sourcemodules are arranged in accordance with any of many of theaforementioned embodiments.

In many of the aforementioned embodiments, the module-based energysystem is configured for operation in an electric or hybrid mobilevehicle. In many of these embodiments, the electric or hybrid mobilevehicle is one of: a car, a bus, a truck, a motorcycle, a scooter, anindustrial vehicle, a mining vehicle, a flying vehicle, a maritimevessel, a locomotive or rail-based vehicle, or a military vehicle.

In many of the aforementioned embodiments, the module-based energysystem is configured for operation as a stationary energy system. Inmany of these embodiments, the stationary energy system is one of: aresidential system, an industrial system, a commercial system, a datacenter storage system, a grid, a micro-grid, or a charging station.

In many of the aforementioned embodiments, the module-based energysystem is configured as a battery pack for an electric vehicle.

In many embodiments, a module-based energy system includes multipleinterconnected converter-source modules and control circuitry, where thecontrol circuitry is configured to adjust power supply to one or more ofthe converter-source modules based on status information associated withone or more of the converter-source modules. In many of theseembodiments, each converter-source module includes a converter-sourcemodule according to many of the aforementioned embodiments.

In many of these embodiments, each converter-source module includes anenergy source including at least one energy storage element, an energybuffer, and a converter. In many of these embodiments, the controlcircuitry is configured to independently determine the amount of chargeeach converter-source module with the system receives from a powersupply external to the system. In many of these embodiments, the controlcircuitry is configured to independently determine the amount of chargeeach converter-source module with the system receives from a powersupply external to the system based on status information associatedwith one or more of the converter-source modules or components thereof,where the status information includes one or more of: state of charge(SOC), state of health (SOH), capacity, temperature, voltage, current,presence of a fault, or absence of a fault. In many of theseembodiments, the multiple converter-source modules are arranged in amulti-dimensional array. In many of these embodiments, the multipleconverter-source modules is arranged in accordance with many of theaforementioned embodiments.

In many embodiments, a converter-source module includes an energy sourceincluding at least one energy storage element, an energy buffer, and aconverter including multiple, the converter configured to generate anoutput voltage based on a combination of the multiple switches.

In many of these embodiments, an output of the energy source iscouplable to an input terminal of the energy buffer. In many of theseembodiments, an output of the energy buffer is couplable to an inputterminal of the converter. In many of these embodiments, the energystorage element is one of an ultra-capacitor, a battery including atleast one cell or multiple battery cells connected in series and/or inparallel, or a fuel-cell. In many of these embodiments, the energybuffer includes one or more of: electrolytic capacitors, filmcapacitors, a Z-source network including two inductors and twocapacitors, or a Quasi Z-source network including two inductors, twocapacitors and a diode. In many of these embodiments, each of themultiple switches includes at least one of a semiconductor MOSFET or asemiconductor IGBT. In many of these embodiments, the converter isconfigured to generate three different voltage outputs by differentcombinations of the multiple switches. In many of these embodiments, theenergy source is configured to output a direct current voltage VDC, andthe three different voltage outputs are +VDC, 0, and −VDC. In many ofthese embodiments, the converter-source module is configured to receiveswitching signals for the multiple switches from a local control device.

In many embodiments, an energy system includes at least twoconverter-source modules according to many of the aforementionedembodiments.

In many of these embodiments, the at least two converter-source modulesare interconnected in one of a one-dimensional array or amulti-dimensional array. In many of these embodiments, a least twoone-dimensional arrays are connected together at different rows andcolumns directly or via additional converter-source modules. In many ofthese embodiments, the energy system includes at least two local controldevices, one local control device for each converter-source module. Inmany of these embodiments, each local control device manages energy fromthe energy source, protects the energy buffer, and controls theconverter.

In many embodiments, a module-based energy system includes a localcontrol device and a converter-source module interconnected to the localcontrol device, where the converter-source module includes an energysource having a storage element, first and second outputs of the energysource being connected to first and second inputs of an energy buffer,first and second outputs of the energy buffer being connected to firstand second inputs of a converter, the converter including at least fourswitches to generate three voltage levels including a first voltagelevel with a positive polarity, a zero or reference voltage level, andthe first voltage level with a negative polarity, where the threevoltage levels are generated by connection of the first voltage levelbetween the first and second inputs of the converter to first and secondoutputs of the converter by different combinations of the at least fourswitches.

In many of these embodiments, the storage element includes one of anultra-capacitor, a battery module including one or more interconnectedbattery cells, and a fuel-cell module. In many of these embodiments, theenergy buffer includes one of an electrolytic and/or film capacitor, aZ-source network formed by two inductors and two electrolytic and/orfilm capacitors, and a Quasi Z-source network formed by two inductors,two electrolytic and/or film capacitors and a diode. In many of theseembodiments, the switches are configured as semiconductor switches. Inmany of these embodiments, the energy source includes a primary energysource and a secondary energy source, where in the primary energy sourceincludes a storage element including one of an ultra-capacitor, abattery module including one or more interconnected battery cells, and afuel-cell module. In many of these embodiments, the first and secondoutputs of the primary energy source are coupled to first and secondinput terminals of an energy buffer, where the energy buffer includesone of an electrolytic and/or film capacitor, a Z-source network formedby two inductors and two electrolytic and/or film capacitors, and aQuasi Z-source network formed by two inductors, two electrolytic and/orfilm capacitors and a diode. In many of these embodiments, a secondoutput of the energy buffer is connected to a second output of thesecondary energy source, and where a first output of the secondaryenergy source is connected to the second input of the converter. In manyof these embodiments, the secondary energy source includes a storageelement including one of an electrolytic and/or film capacitor, anultra-capacitor, a battery module including one or more interconnectedbattery cells, an electrolytic and/or film capacitor connected inparallel with an ultra-capacitor, an electrolytic and/or film capacitorconnected in parallel with a battery module including one or moreinterconnected battery cells, an electrolytic and/or film capacitorconnected in parallel with ultra-capacitor and battery module includingone or more interconnected battery cells. In many of these embodiments,the converter includes six switches. In many of these embodiments, theconverter-source module is configured to power first and secondauxiliary loads.

In many of these embodiments, the system further includes a balancingcontroller. In many of these embodiments, the balancing controller is asingle phase balancing controller. In many of these embodiments, thebalancing controller includes a peak detector, a divider and anintra-phase balancing controller. In many of these embodiments, thesystem further includes multiple converter-source modules, and thebalancing controller is configured to balance state of charge andtemperature among the multiple converter-source modules of the system.In many of these embodiments, the balancing controller is a three phasebalancing controller. In many of these embodiments, the balancingcontroller includes an interphase balancing controller and a multipleintra-phase controllers. In many of these embodiments, the systemfurther includes multiple converter-source modules, and the balancingcontroller is configured to balance state of charge and temperatureamong the multiple converter-source modules of the system.

In many embodiments, a module-based energy system is provided, includinga converter-source module, including: a first energy source; and aconverter coupled with the first energy source, wherein the converterincludes multiple switches configured to select an output voltage of themodule.

In many embodiments, a method of supplying an output power from amodule-based energy system is provided, the method including: receiving,by control circuitry of the system, status information from at least oneof multiple converter-source modules of the system, wherein eachconverter-source module includes an energy source and a converter andwherein each converter-source module is configured to contribute powerto an output power of the system; and controlling, by the controlcircuitry, a power contribution of at least one converter-source moduleof the multiple converter-source modules based on the statusinformation.

In these embodiments, the control circuitry can include a master controldevice and multiple local control devices. The master control device canreceive the status information from at least one local control device,and the method can further include outputting a reference waveform and amodulation index from the master control device to the at least onelocal control device. The method can further include: modulating, by thelocal control device, the reference waveform with the modulation index;and generating multiple switching signals for a converter of aconverter-source module associated with the local control device based,at least in part, on the modulated reference waveform. The switchingsignals can be generated with pulse width modulation.

In these embodiments, controlling, by the control circuitry, the powercontribution of the at least one converter-source module can include:generating and outputting multiple switching signals from the controlcircuitry to the converter of the at least one converter-source module,wherein the method further includes switching, by the converter, anoutput voltage of the at least one converter-source module.

In these embodiments, controlling, by the control circuitry, the powercontribution of the at least one converter-source module can include:reducing the power contribution of the at least one converter-sourcemodule or raising the power contribution of the at least oneconverter-source module. The power contribution can be reduced or raisedas compared to a preceding power contribution of the at least oneconverter-source module or as compared to the power contribution of oneor more other converter-source modules.

In these embodiments, the control circuitry can control the powercontribution of every converter-source module of the multipleconverter-source modules.

In these embodiments, the control circuitry can control the powercontribution according to a pulse width modulation or hysteresistechnique.

In these embodiments, the control circuitry can repeatedly receivestatus information for every converter-source module, wherein the statusinformation is specific to each individual converter-source module. Thecontrol circuitry can control every converter-source module based on thestatus information, wherein the control occurs in real time.

In many embodiments, a method of charging a module-based energy systemis provided that includes: receiving, by control circuitry of thesystem, status information from at least one of multipleconverter-source modules of the system, wherein each converter-sourcemodule includes an energy source and a converter and wherein eachconverter-source module is configured to be charged by a power supply;and controlling, by the control circuitry, a power consumption of atleast one converter-source module of the multiple converter-sourcemodules based on the status information.

In these embodiments, controlling, by the control circuitry, the powerconsumption of the at least one converter-source module can include:generating and outputting multiple switching signals from the controlcircuitry to the converter of the at least one converter-source module,and wherein the method can further include switching, by the converter,multiple switches such that the power consumption of at least oneconverter-source module is reduced or raised, optionally wherein thepower consumption is reduced or raised as compared to a preceding powerconsumption of the at least one converter-source module or as comparedto the power consumption of one or more other converter-source modules.

Processing circuitry can include one or more processors,microprocessors, controllers, and/or microcontrollers, each of which canbe a discrete or stand-alone chip or distributed amongst (and a portionof) a number of different chips. Any type of processing circuitry can beimplemented, such as, but not limited to, personal computingarchitectures (e.g., such as used in desktop PC's, laptops, tablets,etc.), programmable gate array architectures, proprietary architectures,custom architectures, and others. Processing circuitry can include adigital signal processor, which can be implemented in hardware and/orsoftware. Processing circuitry can execute software instructions storedon memory that cause processing circuitry to take a host of differentactions and control other components.

Processing circuitry can also perform other software and/or hardwareroutines. For example, processing circuitry can interface withcommunication circuitry and perform analog-to-digital conversions,encoding and decoding, other digital signal processing, multimediafunctions, conversion of data into a format (e.g., in-phase andquadrature) suitable for provision to communication circuitry, and/orcan cause communication circuitry to transmit the data (wired orwirelessly).

Any and all signals described herein can be communicated wirelesslyexcept where noted or logically implausible. Communication circuitry canbe included for wireless communication. The communication circuitry canbe implemented as one or more chips and/or components (e.g.,transmitter, receiver, transceiver, and/or other communicationcircuitry) that perform wireless communications over links under theappropriate protocol (e.g., Wi-Fi, Bluetooth, Bluetooth Low Energy, NearField Communication (NFC), Radio Frequency Identification (RFID),proprietary protocols, and others). One or more other antennas can beincluded with communication circuitry as needed to operate with thevarious protocols and circuits. In some embodiments, communicationcircuitry can share antenna for transmission over links. Processingcircuitry can also interface with communication circuitry to perform thereverse functions necessary to receive a wireless transmission andconvert it into digital data, voice, and/or video. RF communicationcircuitry can include a transmitter and a receiver (e.g., integrated asa transceiver) and associated encoder logic.

Processing circuitry can also be adapted to execute the operating systemand any software applications, and perform those other functions notrelated to the processing of communications transmitted and received.

Computer program instructions for carrying out operations in accordancewith the described subject matter may be written in any combination ofone or more programming languages, including an object orientedprogramming language such as Java, JavaScript, Smalltalk, C++, C #,Transact-SQL, XML, PHP or the like and conventional proceduralprogramming languages, such as the “C” programming language or similarprogramming languages.

Memory, storage, and/or computer readable media can be shared by one ormore of the various functional units present, or can be distributedamongst two or more of them (e.g., as separate memories present withindifferent chips). Memory can also be a separate chip of its own.

To the extent the embodiments disclosed herein include or operate inassociation with memory, storage, and/or computer readable media, thenthat memory, storage, and/or computer readable media are non-transitory.Accordingly, to the extent that memory, storage, and/or computerreadable media are covered by one or more claims, then that memory,storage, and/or computer readable media is only non-transitory. Theterms “non-transitory” and “tangible” as used herein, are intended todescribe memory, storage, and/or computer readable media excludingpropagating electromagnetic signals, but are not intended to limit thetype of memory, storage, and/or computer readable media in terms of thepersistency of storage or otherwise. For example, “non-transitory”and/or “tangible” memory, storage, and/or computer readable mediaencompasses volatile and non-volatile media such as random access media(e.g., RAM, SRAM, DRAM, FRAM, etc.), read-only media (e.g., ROM, PROM,EPROM, EEPROM, flash, etc.) and combinations thereof (e.g., hybrid RAMand ROM, NVRAM, etc.) and variants thereof.

It should be noted that all features, elements, components, functions,and steps described with respect to any embodiment provided herein areintended to be freely combinable and substitutable with those from anyother embodiment. If a certain feature, element, component, function, orstep is described with respect to only one embodiment, then it should beunderstood that that feature, element, component, function, or step canbe used with every other embodiment described herein unless explicitlystated otherwise. This paragraph therefore serves as antecedent basisand written support for the introduction of claims, at any time, thatcombine features, elements, components, functions, and steps fromdifferent embodiments, or that substitute features, elements,components, functions, and steps from one embodiment with those ofanother, even if the following description does not explicitly state, ina particular instance, that such combinations or substitutions arepossible. It is explicitly acknowledged that express recitation of everypossible combination and substitution is overly burdensome, especiallygiven that the permissibility of each and every such combination andsubstitution will be readily recognized by those of ordinary skill inthe art.

As used herein and in the appended claims, the singular forms “a,” “an,”and “the” include plural referents unless the context clearly dictatesotherwise.

While the embodiments are susceptible to various modifications andalternative forms, specific examples thereof have been shown in thedrawings and are herein described in detail. It should be understood,however, that these embodiments are not to be limited to the particularform disclosed, but to the contrary, these embodiments are to cover allmodifications, equivalents, and alternatives falling within the spiritof the disclosure. Furthermore, any features, functions, steps, orelements of the embodiments may be recited in or added to the claims, aswell as negative limitations that define the inventive scope of theclaims by features, functions, steps, or elements that are not withinthat scope.

What is claimed is:
 1. A modular battery pack system controllable tosupply power to an electric vehicle (EV), the modular battery packsystem comprising: three converter module arrays, each array comprisingat least three arrayed converter modules electrically coupled togetherto output an AC voltage signal comprising a superposition of outputvoltages from each of the three arrayed converter modules, wherein eachof the three arrays is configured to output an AC voltage signal havinga different phase angle for a three phase motor of the EV, and whereineach of the arrayed converter modules comprises an energy source and iscontrollable to selectively output a positive DC output voltage, zerooutput voltage, or negative DC output voltage from the energy source;and a first interconnection module electrically coupled with a firstarray of the three converter module arrays and a second array of thethree converter module arrays, wherein the first interconnection modulecomprises a first battery and a first port to supply power from thefirst battery to a first auxiliary load of the EV; and a secondinterconnection module electrically coupled with a third array of thethree converter module arrays, wherein the second interconnection modulecomprises a second battery, electrically coupled in parallel with thefirst battery, and a second port to supply power from the second batteryto the first auxiliary load of the EV.
 2. The system of claim 1, whereinthe first battery is configured to output a first voltage, and whereinthe first interconnection module is configured to supply the firstvoltage directly to the first auxiliary load.
 3. The system of claim 1,wherein the first interconnection module comprises: first switchcircuitry electrically coupled with the first battery; and a firstinductor electrically coupled with the first switch circuitry such thatthe first inductor is switchably coupled to the first battery, whereinthe first inductor is electrically coupled with the first port.
 4. Thesystem of claim 3, further comprising control circuitry configured tocontrol the first switch circuitry to control the first voltage suppliedto the first auxiliary load from the first battery.
 5. The system ofclaim 4, wherein the control circuitry is configured to receivemeasurement signals from the first interconnection module and use themeasurement signals to control the first switch circuitry to control thefirst voltage supplied to the first auxiliary load.
 6. The system ofclaim 5, wherein the control circuitry is configured to use themeasurement signals and to generate a pulse width modulated switchsignal to control the first switch circuitry to control the firstvoltage supplied to the first auxiliary load.
 7. The system of claim 1,wherein the first auxiliary load comprises an air conditioner of the EV,and the second auxiliary load is an on-board electrical network of theEV.
 8. The system of claim 1, wherein the first interconnection modulecomprises first switch circuitry electrically coupled with the first andsecond batteries, and a first inductor electrically coupled with thefirst switch circuitry such that the first inductor is switchablycoupled to the first and second batteries, wherein the first inductor iselectrically coupled with the first port.
 9. The system of claim 8,wherein the second interconnection module comprises second switchcircuitry electrically coupled with the first and second batteries, anda second inductor electrically coupled with the second switch circuitrysuch that the second inductor is switchably coupled to the first andsecond batteries, wherein the second inductor is electrically coupledwith the second port.
 10. The system of claim 1, wherein the firstinterconnection module comprises a third port to supply power from thefirst and second batteries to a second auxiliary load of the EV.
 11. Thesystem of claim 10, wherein the second interconnection module comprisesa fourth port to couple to a second auxiliary load of the EV.
 12. Thesystem of claim 11, wherein the first and second ports are electricallycoupled together, and wherein the third and fourth ports areelectrically coupled together.
 13. The system of claim 1, wherein thefirst array has a first end with a first end terminal that outputs theAC voltage signal of the first array to the three phase motor, and asecond end, opposite the first end, with a second end terminal that isconnected to the first interconnection module.
 14. The system of claim13, wherein the second array has a first end with a first end terminalthat outputs the AC voltage signal of the second array to the threephase motor, and a second end, opposite the first end, with a second endterminal that is connected to the first interconnection module, andwherein the third array has a first end with a first end terminal thatoutputs the AC voltage signal of the third array to the three phasemotor, and a second end, opposite the first end, with a second endterminal that is connected to the second interconnection module.
 15. Amethod of supplying power from a modular battery pack system to anelectric vehicle (EV), the method comprising: controlling threeconverter module arrays to output three phase voltage signals to a threephase motor of the EV, wherein each array comprises at least threearrayed converter modules electrically coupled together to output an ACvoltage signal comprising a superposition of output voltages from eachof the three arrayed converter modules, wherein each of the arrayedconverter modules comprises an energy source and is controllable toselectively output a positive DC output voltage, zero output voltage, ornegative DC output voltage from the energy source; controlling a firstinterconnection module to supply power from a first battery of the firstinterconnection module to a first auxiliary load of the EV, wherein thefirst interconnection module is electrically coupled with a first arrayof the three converter module arrays and a second array of the threeconverter module arrays, wherein the first interconnection modulecomprises the first battery and a first port to supply power from thefirst battery to the first auxiliary load, and controlling a secondinterconnection module to supply power from a second battery of thesecond interconnection module to the first auxiliary load, wherein thesecond interconnection module is electrically coupled with a third arrayof the three converter module arrays, and wherein the secondinterconnection module comprises the second battery, electricallycoupled in parallel with the first battery, and a second port to supplypower from the second battery to the first auxiliary load.
 16. Themethod of claim 15, wherein controlling the first interconnection modulecomprises: controlling first switch circuitry of the firstinterconnection module to control the power supplied from the firstbattery to the first auxiliary load.
 17. The method of claim 16, furthercomprising: using measurement signals from the first interconnectionmodule to control the first switch circuitry to control the powersupplied from the first battery to the first auxiliary load.
 18. Themethod of claim 17, wherein using the measurement signals from the firstinterconnection module comprises: using the measurement signals as abasis to generate a pulse width modulated switch signal to control thefirst switch circuitry to control the power supplied to the firstauxiliary load.
 19. The method of claim 18, wherein the firstinterconnection module comprises: a first inductor electrically coupledwith the first switch circuitry such that the first inductor isswitchably coupled to the first battery, wherein the first inductor iselectrically coupled with the first port and power is supplied from thefirst battery to the first auxiliary load through the first inductor.20. The method of claim 15, wherein the first interconnection modulecomprises first switch circuitry, electrically coupled with the firstand second batteries, and a first inductor electrically coupled with thefirst switch circuitry such that the first inductor is switchablycoupled to the first and second batteries, wherein the first inductor iselectrically coupled with the first port.
 21. The method of claim 20,wherein the second interconnection module comprises second switchcircuitry, electrically coupled with the first and second batteries, anda second inductor electrically coupled with the second switch circuitrysuch that the second inductor is switchably coupled to the first andsecond batteries, wherein the second inductor is electrically coupledwith the second port.
 22. The method of claim 15, further comprisingsupplying power from the first interconnection module to a secondauxiliary load of the EV.
 23. The method of claim 15, wherein the firstarray has a first end with a first end terminal that outputs the ACvoltage signal of the first array to the three phase motor, and a secondend, opposite the first end, with a second end terminal that isconnected to the first interconnection module.
 24. The method of claim23, wherein the second array has a first end with a first end terminalthat outputs the AC voltage signal of the second array to the threephase motor, and a second end, opposite the first end, with a second endterminal that is connected to the first interconnection module, andwherein the third array has a first end with a first end terminal thatoutputs the AC voltage signal of the third array to the three phasemotor, and a second end, opposite the first end, with a second endterminal that is connected to the second interconnection module.